Progress Through Purpose
UR PARTNER FOR RFORMANCE
UMINUM CASTINGS
pressure anent mold permanent mold treating ng services
years of foundry operating expertise, trust with: collaborative approach
We work hand-in-hand with you as an perational team to ensure your project s a success.
dvanced capabilities
imulation, tooling design, real-time process ata, automation, quality assurance.
Deep expertise
Decades of industry knowledge and xperienced leadership combined with the atest software and technologies.
128 Oakland Avenue, London, Ontario, Canada
Progress Through Purpose With decades of expertise, Dayton-Phoenix Group delivers innovative solutions that meet the highest standards of quality and performance for critical heavy industry applications. We get the full story from CCO, John Gordon Writer: Ed Budds | Project Manager: Poppi Burke
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DAYTON-PHOENIX GROUP MANUFACTURING
S
ince 1939, Dayton-Phoenix Group (DPG) has been at the heart of heavy industry – designing, engineering, and manufacturing electrical and mechanical solutions that keep railroads, mining operations, and offhighway equipment running at peak performance. Born from a proud tradition of American innovation in the heartland, the company has spent generations solving the toughest challenges in the
harshest industries. “We design and manufacture electric motors, dynamic braking systems and resistors, cooling fans and blowers, locomotive heating, ventilation, and air conditioning (HVAC) systems, and other engineered solutions primarily for the rail and mining industries,” introduces CCO, John Gordon. Today, DPG employs more than 350 people and operates over 700,000 square feet of manufacturing and
service facilities across the US. “Our primary manufacturing operations are in Dayton, Ohio and West Lafayette, Indiana, while our remanufacturing facilities in Houston, Texas and Gothenburg, Nebraska provide lifecycle support for our customers’ critical equipment,” he lists. Today, its customers include many of the world’s leading original equipment manufacturers (OEMs), railroads, mining companies, and fleet operators.
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“As both an OEM supplier and a trusted aftermarket partner, we support customers around the world with engineered solutions that keep critical operations running while improving performance, reducing lifecycle costs, and preparing for the future of electrification,” Gordon sets out.
INDUSTRY IN TRANSITION Right now, across the vast landscape of US manufacturing, particularly in rail and heavy industry, there is tremendous pressure to improve efficiency, reduce operating costs, modernize aging equipment, and strengthen domestic manufacturing, while new technologies are creating opportunities that simply weren’t available before. Meanwhile, one of the biggest trends on the rise is a more practical approach to electrification and sustainability. While reducing emissions remains an important objective, the conversation has shifted toward improving the total cost of ownership. Customers are looking for solutions that reduce fuel consumption, maintenance costs, downtime, and overall operating expenses, but the economics must make sense. 4 | North America Outlook Issue 37
COULD YOU TALK ABOUT YOUR RECENT INVESTMENT IN AUTOMATION? John Gordon, CCO: “Automation is a key part of our long-term strategy, but perhaps not in the way many people think about it. “DPG’s core purpose has always been centered on creating jobs and building careers, so we don’t view automation as a way to replace people or reduce our workforce. Instead, we see it as a tool that enables our employees to produce higher-quality products more consistently while allowing us to meet growing customer demand. “As our business grows, particularly in our new products, we expect production volumes to increase significantly. Investing in automation today helps ensure we’re ready for that growth by improving quality, increasing throughput, and creating safer, more repeatable manufacturing processes. “We’re already implementing automation in several areas, including stamping, welding, and the production of braking resistor assemblies. At the same time, we’re evaluating how automation can support the next generation of electric motor manufacturing as we expand our electrification portfolio, allowing us to scale production while maintaining the quality and reliability our customers expect. “For us, automation isn’t about replacing skilled people – it’s about giving them better tools. Our employees bring the expertise, problem-solving, and innovation that machines simply can’t replace.”
DAYTON-PHOENIX GROUP MANUFACTURING
Replacing entire fleets of expensive assets is rarely practical, creating a significant opportunity to modernize and improve equipment already in service. “We’re also currently watching the emergence of autonomous rail operations. These technologies have already demonstrated their value in mining, and we believe freight rail is beginning a similar evolution,” observes Gordon. As these technologies mature, they have the potential to make rail transportation more flexible, improve asset utilization, enhance safety, lower operating costs, and ultimately allow rail to capture freight that has traditionally moved by truck. For DPG, these industry trends align directly with its strategy. “Our focus isn’t on technology for technology’s sake – it’s on developing practical, reliable, and commercially viable solutions that deliver measurable value for our customers. “We understand the equipment they operate today, where it can be improved, and how to apply new technologies in ways that strengthen performance, reduce operating costs, and provide a clear return on investment,” Gordon muses. That’s what makes this such an exciting time for the industry and why the company remains so optimistic about where it’s heading.
“Our focus isn’t on technology for technology’s sake – it’s on developing practical, reliable, and commercially viable solutions that deliver measurable value for our customers” – J O H N G O R D O N , C C O , D AY T O N - P H O E N I X G R O U P
SERVICE WITH A DIFFERENCE Gordon believes what truly differentiates DPG is a deep understanding of the industries it serves. “We don’t simply manufacture products – we understand the applications, operating environments, and challenges our customers face every day,” highlights Gordon. Whether it’s a locomotive operating in extreme climates or mining equipment running around the clock, the company’s solutions are designed specifically for demanding conditions. North America Outlook Issue 37 | 5
DAYTON-PHOENIX GROUP MANUFACTURING
“Our products have earned a reputation for robustness, reliability, and long service life. Customers depend on our equipment because downtime is extremely costly, so durability and performance are never compromised,” he prides. That focus on quality has helped build relationships with customers that span decades. Just as important is DPG’s commitment to putting the customer first, working closely to understand their operational goals and develop solutions that solve real problems rather than offering one-size-fits-all products. “That collaborative approach has made us a trusted engineering partner, not just a supplier,” Gordon affirms. Another significant competitive advantage for DPG is its people. With decades of experience in both the rail and mining industries, their expertise allows the company to anticipate challenges, innovate with purpose, and deliver solutions that provide real value. “As these industries transition toward electrification, we’re combining deep industry knowledge with new technologies to ensure
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our customers receive practical, commercially viable solutions that improve performance and lower the total cost of ownership,” he assures.
THE PATH TO INNOVATION One project that the company is especially proud of is VOLT, its portable battery-electric and hybrid solution for locomotives. Rather than replacing an existing diesel-electric locomotive with an entirely new asset, VOLT is designed to work with the locomotive a railroad already owns, using battery energy to offset diesel-generated power
while retaining the diesel engine when needed. “A key part of VOLT is its modular, swappable approach. Instead of tying up a locomotive for hours while batteries charge, the goal is to exchange the energy storage and keep the locomotive working,” Gordon explains. What makes VOLT special to DPG is that it represents exactly how the company believes change should happen – by taking an enormous industry challenge, finding a practical solution with a real economic return, then going and proving it.
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WHY RAMSDEN?
With 80 years of foundry operating expertise, we build trust with:
Family-owned. Customer-focused. Built on science. Backed with expertise. As a family business, we treat every customer relationship like a partnership. We are fully committed to your success – it is why our customers stay committed to us.
A collaborative approach We work hand-in-hand with you as an operational team to ensure your project is a success. Advanced capabilities Simulation, tooling design, real-time process data, automation, quality assurance. Deep expertise Decades of industry knowledge and experienced leadership combined with the latest software and technologies.
sales@ramsden.ca www.ramsden.ca
+1.519.451.6720
128 Oakland Avenue, London, Ontario, Canada
DAYTON-PHOENIX GROUP MANUFACTURING
“We’ve already demonstrated the fundamental technology on a locomotive at MxV Rail in Pueblo, Colorado, and we’re now working toward the next phase of larger-scale testing and real-world operation,” he informs us. VOLT isn’t about electrification for the sake of electrification – it’s about giving railroads a practical path to reduce fuel consumption and operating costs using the assets and infrastructure they already have.
CATALYST FOR CHANGE DPG has several other electrification projects in development that apply 8 | North America Outlook Issue 37
the same philosophy to different parts of rail, mining, and heavy industry. In this realm, the company is developing SYNC, which captures energy from regenerative braking on large electric-drive haul trucks, stores it, and puts that energy back to work rather than simply dissipating it as heat. “We’ve also developed CATALYST, our permanent magnet motor, which can serve as a key component in solutions that convert traditionally mechanical-drive mining haul trucks to electric drive,” Gordon tells us. That type of conversion requires collaboration with other technology
partners, but it’s another example of where DPG’s core expertise can help enable larger electrification solutions. In rail, the company is also working on a compact integrated motor and drive solution aimed at enabling self-propelled railcars without the complexity of a traditional drivetrain. “What excites me most is that we’re moving beyond talking about what electrification could look like someday,” he enthuses. DPG already has a significant footprint as an OEM supplying equipment throughout the rail and mining industries, which gives it an incredible foundation to build from. “We understand the equipment, applications, and customers. We’re taking technologies and expertise DPG already has and putting them together in new ways, often alongside great industry partners, to solve real problems today,” asserts Gordon.
INVESTING FOR THE FUTURE The next three to five years will be a defining period for DPG.
DAYTON-PHOENIX GROUP MANUFACTURING
“ We d o n ’ t s i m p l y m a n u f a c t u r e products – we understand the applications, operating environments, and challenges our customers face every day” – J O H N G O R D O N , C C O , D AY T O N - P H O E N I X G R O U P
The company is preparing to launch several major new products that will fundamentally redefine the business, expanding it from a long-established manufacturer of proven rail and industrial products into a leader in next-generation electrification technologies for the rail and mining industries. “Successfully bringing these products to market and scaling production is our highest priority. These programs represent years of engineering, customer collaboration,
and strategic investment, and we believe they will position DPG for significant long-term growth,” Gordon excites. Just as important as financial growth is preserving the culture that has made DPG successful. “As we grow, we are committed to maintaining a culture that values our people, encourages collaboration and innovation, and stays true to our core purpose of serving our communities, creating jobs, and providing opportunities for our team
members to be the best they can be,” he outlines. Moreover, the company believes sustainable growth is achieved by not only investing in technology, but also continuing to invest in its people. While the business is evolving rapidly, one thing will remain unchanged – DPG’s commitment to developing commercially viable solutions that solve real customer challenges. “Our goal isn’t simply to become a larger company – it’s to redefine what DPG represents in the marketplace and become the preferred partner for innovative, reliable technologies that power the future of heavy industry,” Gordon finishes.
Tel: (937) 496-3900
www.dayton-phoenix.com North America Outlook Issue 37 | 9
Tel: (937) 496-3900 www.dayton-phoenix.com
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