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 Looks to Another Year of Fare Free
By Breanna SteeleiBerkshires Staff
PITTSFIELD, Mass. — The BRTA is expecting another year of fare free rides.
Berkshire Regional Transit Authority Administrator Kathleen Lambert told the advisory board recently that she expects to receive $1.3 million in state funding to remain fare free. She said RTAs may be given up to $40 million this year statewide, which is $5 million up from last year.
While the state budget is not formally approved yet, the effect will take place on July 1.
The news came at the same time the board approved the BRTA's budget of $13.6 million, which is an increase of 11 percent since last fiscal year.
Some of the increases were in the fixed route area which jumped from $9 million to $12 million. Lambert said this is due to the contractual agreement between the union where they have a five percent raise for all of the drivers and other union members, as well as a seven percent raise for paratransit fleet operators.
Lambert said much of the costs raised were fuel costs because of the ongoing war in Iran. The authority uses about 8,000 gallons of fuel a month and has planned for $5.75 per gallon.
The customer service desk, which currently staffs two employees, will be shut down, she said. The two employees were given notice months in advance and one showed interest in becoming a bus driver and will plan to interview for that. Lambert said two new drivers have started and that the new transit company Keolis, which is taking over for Transdev, will continue to hold recruiting events. The new manager is Mark Moujabber, taking over for Bobby Quintos.
Lambert told the board she believed there are discrepancies in ridership data. Deputy Administrator Benjamin Hansen, who was in operations before his current role, said the authority has been seeing low ridership because of route cancellations, however, this past month, the numbers did not make sense as demand has stayed the same but ridership seemed exponentially low.
To get the figures, bus drivers must manually push a button on the farebox to record passengers, wheelchairs, and bikes, which might have errors. There are automatic passenger counters (APCs) installed, but they are not certified, so are only used as a rough comparison tool as they are not accurate.
Board member Stuart Lawrence asked if there has been any investigation on if this might be deliberate. Hansen said there is not as he does not know how they could watch for that to happen.
Lambert said she has been working with professor Paula Consolini at Williams College, who will have a group of samplers who will ride the bus and gather a week's worth of data.
In the last meeting, the board spoke about anonymous emails from drivers, and 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.
Multiple employees had also signed on to a vote of no confidence letter in the BRTA administration spearheaded by Raymond Killeen who is a bus driver and represents Cheshire on the advisory board. Killeen said losing Quintos was hard, stating he was an excellent general manager and not having him there led to hardships on accomplishing many things.
"Once the removal was there, it was difficult to accomplish certain things, because we had lost the general manager. So, the letter was an attempt to get things moving a little bit quicker, so we could provide a better service for the residents of Berkshire County. I don't know if it accomplished that. We were able to do some things, though, but the concern amongst rank and file here is that we're not providing the best service we possibly could, and we're hoping that when the new management team comes in, that can be accomplished," Killeen said.
Killeen said he was unhappy with the progress to a revised driver schedule. The day after the meeting, Lambert and the team had a meeting to discuss and negotiate run schedules, Lambert said it was a very good and productive meeting.
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