Lenco President and CEO Len Light, left, holds the ribbon as general manager Kristin Light cuts it at Monday's celebration of the company's new laser sheet metal cutter. The $2 million machine is expected to boost BearCat production by 40 percent.
BIC director Benjamin Sosne says he holds up Lenco as a model for startups.
Light says the new machine — a far cry from the old oxyacetylene torches — fills him with confidence about the company's future.
A technician gives a rundown on how the laser cutter works.
Executive Vice President Lenny Light says it's not the equipment but the staff that gives Lenco its competitive advantage.
PITTSFIELD, Mass. — Lenco Armored Vehicles has embarked on a $5 million capital investment project for faster, better manufacturing.
A ribbon was cut on Monday in front of the company's new Trumpf TruLaser 3080, a machine designed to cut extra-large sheets of metal. This will increase the efficiency of building armored tactical vehicles, such as the BearCat, by about 40 percent.
Executive Vice President Lenny Light recalled the Lenco's beginnings in 1981, when it operated out of 3,000 square feet on Merrill Road with 15 employees. Today, Lenco has 170,000 square feet of manufacturing space and nearly 150 employees.
"The work that we do here in Pittsfield contributes to millions of dollars being put back into our local economy. We're the largest commercial armored rescue vehicle manufacturer in the United States. We're one of the most respected brands locally. We also now own the largest fiber laser in the United States. It's the only one of its kind in the Northeast," he said, motioning to the massive, modern machinery.
"But the equipment that we have is not our competitive advantage — our welders, our forklifts, our cranes — any company can buy this same exact equipment."
Rather than the equipment, he said, it's the staff who shows up every day with a can-do attitude that gives Lenco its competitive advantage.
Planning for the industrial cutter began 18 months ago, when the company needed to decide if it was the right equipment for the future. Trumpf, named for its founder, is a German-headquartered global manufacturer of high-end metal processing (computer numerical control) machines, including laser technology. The TruLaser 3080 uses a high-intensity laser beam to cut through metals with speed and accuracy.
Over several months, a 12-page research paper was compiled about how the Trumpf machine could benefit production, and Light said it was "very clear" that it would make Lenco faster, higher quality, and more innovative.
It cuts material 300 percent faster than the old machine, and is expected to make overall production an average of 20 to 30 percent faster when fully integrated. There were more than 3,000 parts that had to be redesigned for the machine, and until last week, the production space was being rearranged to accommodate the flow of material.
The machine cost nearly $2 million, and the company received a $200,000 grant from the Massachusetts Technology Collaborative for the effort.
Lily Fitzgerald, director of MassTech's Center for Advanced Manufacturing, said the state is unique for having a team dedicated to supporting manufacturing. Massachusetts has 6,000 manufacturers, and the sector contributes 10 percent and growing of its Gross Domestic Product.
"There is so much of manufacturing that is unseen and underappreciated. I love coming to Pittsfield because I know that that's not true in this town," she said.
"This town understands the power of this industry, because you live and you breathe it every day."
Funds were awarded through the Massachusetts Manufacturing Accelerator Program, which helps manufacturers scale up, modernize, automate, and meet customer demand. Fitzgerald said she wishes every company came to her office with a 12-page plan on how to leverage a piece of equipment and make sure it is the best use for taxpayer dollars.
"You're best in class for that," she said.
Light said the program, in a way, inspired Lenco officials to think big, and what started as about a half-million dollar investment in welding equipment turned into a $3 million investment in advanced CNC technology.
His father, President and CEO Len Light, remembers when the steel was cut with oxyacetylene torches and is pleased to see the advances in technology. This project fills him with confidence that the company's future is good, and he hopes this investment demonstrates its commitment to continuous improvement in manufacturing and product quality.
"We got our first Hypertherm handheld plasma cutter in the mid-80s, which was when it was invented. Some of you weren't even born at that time," he said.
"We've come a long way since then, and I can't be proud enough of our next generation of leadership who spearheaded this project and successfully executed its implementation that we're celebrating here today."
Light added that the BearCat (Ballistic Engineered Armored Response Counter Attack Truck) is a proven vehicle that saves lives. Lenco has good reason to celebrate, as it is busier than ever and will be able to meet increasing BearCat demand with these improvements.
Berkshire Innovation Center Executive Director Benjamin Sosne said he sees evolution every time he visits the Betnr Industrial Drive facility and credited the Lenco team for being committed to improvement and efficiency. He tells young startups coming into the BIC about the origins of the BearCat, and says, "Look at Lenco now."
He commended the company for leveraging state resources to upgrade equipment.
"You didn't just go out and buy something. You really thought through what was going to be a long-term solution and long-term growth for the company, and it ended up much bigger than you originally started," Sosne said.
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BRTA Focuses on a New Run Schedule
By Breanna SteeleiBerkshires Staff
PITTSFIELD, Mass. — The Berkshire Regional Transit Authority is still working on maintaining its run schedules after dropping the route realignment proposal.
Last Thursday's meeting was Administrator Kathleen Lambert's first official meeting taking over the reins; retiring director Robert Malnati stayed during a transition period that ended last month.
Lambert is trying to create a schedule that will lessen cancellations. There was a two-hour meeting the week before with the drivers union to negotiate run bids and Lambert is working with the new operating company Keolis, which is taking over from Transdev.
The board spoke about anonymous emails from drivers, which Lambert said she has not seen. iBerkshires was not able to see those letters, but has received some.
"They were lengthy emails from someone describing themselves as concerning BRTA employee, and there was a signed letter from a whole group of employees basically stating their concerns. So, you know, to me, it was a set of whistleblowers, and that, what my understanding is that this really triggers a need for some type of process to review the merits of these whistleblowers, not going to call them accusations, but basically expressions of concern," said member Stephen Bannon.
A letter iBerkshires received spoke of unhappy drivers who were considering quitting because of decisions being made without "input from frontline staff," frustration and falling morale, and the removal of the former general manager shortly after Lambert came in.
Lambert said it's difficult to navigate a new change. She also noted many drivers don't want to do Saturday runs and it has been hard negotiating with drivers on the new runs.
"I would like you all to keep in mind that the process of change is super difficult. Transdev has been here for 20 years, and some of these drivers have never known any other operating company, the way some of the operations have been handled has been archaic," she said. "So getting folks up to speed on how a modern transit system works is going to be painful for them. So I don't want to say that I'm unsympathetic, because I am sympathetic, but I am trying to coax people along with a system that's going to seem very strange to them."
The board spoke about better communication between them and Lambert, citing cooperation will be best moving forward.
"There's just a lot of stuff in the air right now, and there are a lot of fires to put out to make this a coordinated effort. And if we don't keep our communications open and be straightforward, then you get blindsided about how you know the input that you could get from us about your position, and how you know what's going on in your direction, and we get blindsided. And I think that we have to make sure that this is a collaboration," said member Sherry Youngkin.
"Both sides have responsibilities, because in the long run, this advisory board is going to have to make decisions as to how we brought forward and if we've gone forward in a fair and helpful way. And I think that's hopefully what everybody is looking for also."
Transdev and Keolis held a three-day recruiting event interviewing almost 40 candidates and offering jobs to eight, but only three stayed on to start training. Lambert said it was disappointing but she will keep trying to retain more people.
In her first report to the board, she noted that ridership dipped a little over 10 percent, but still remains higher than last year, adding that was because of cancellations of services because of the lack of drivers.
Like the last meeting, some of the advisory board members were torn over the start of the Link413 service, worried that the start of the service took drivers away and the numbers of riders are low.
Lambert, however, said the ridership has doubled from last month.
"As I've spoken before, we have, generally, a six-month adoption for brand-new service before you can really go in and evaluate, are you being successful based on the grant that my predecessor wrote along with the team for PBTA and RTA, we are ahead of schedule, which is pretty good, so I'm hoping that will continue to improve," she said.
Member Renee Wood said the board never approved the service, adding the only thing she could find in the minutes was a vote to accept the equipment. She said it was supposed to be put on the agenda to discuss.
"The Link413 service has been three years in the making. It's been a grant that was accepted and has been working with our partners, PVTA and FRTA, to put into place. So I don't have the entire history of how that process worked, but it's been three years in the making, and did we not understand that once we accept that grant that we were going to put in new service?" Lambert said.
The board discussed if Title VI, the Civil Rights Act, was followed with an accurate review and accurate amount of time for public comment period on the service changes and if its attorney should review if the grant conditions were properly followed.
Lambert said changes had the 60-day comment period included in the proposed route realignment packet, giving the opportunity for the community to respond to that as well but will look into the legality of the situation with their attorney.
The Berkshire Regional Transit Authority is still working on maintaining its run schedules after dropping the route realignment proposal. click for more
The town election is less than a month away and, unlike recent ones, all open seats are uncontested, with even a vacancy remaining on the Planning Board.
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