The Harley-Davidson Powertrain Operations is part of an extensive manufacturing complex housed in two separate facilities. The Powertrain Operations manufactures engines and transmission parts that are transferred to assembly teams to manufacture their motorcycles. It’s a vital operation—without power trains, there’s no assembly, and without assembly, no distribution or sales. The entire operation grinds to a halt.

CHALLENGE
Powertrain assembly uses a large number of CNC (computer-controlled cutting machines) for heavy-duty metal milling and part fabrication. Facility managers understood that power sags were interfering with the pumps, which in turn impacted hydraulics. The net result: dormant equipment, stalled operations, and extensive part damage and waste.

SOLUTION
After convincing upper management of the cause—and the cure—plant managers worked with us to develop the best solution. The Harley-Davidson power supply runs from a main distribution point into four separate subpanels inside the plant, so four process-level MegaDySC battery-free UPSs (1200 and 2000 amp) were installed to protect each major branch from power sags.

RESULTS
The installation was so successful in reducing unscheduled downtime and product waste that Harley-Davidson named us a strategic partner. When their operations were expanded to increase output by 25%, four more MegaDySCs were included as an integral part of the new installation. DySC battery-free UPSs are also being added to protect operations at other factory locations.