Our customer was at a standstill: for 12 long months, one of their vessels had sat dry docked and idle. The culprit? Worn-out engine couplings – small and seemingly insignificant components, yet crucial to the ship’s functionality.
They searched for a solution without success. The original manufacturer said they could help, but after months of waiting, the replacement parts never arrived – and then told our customer they could no longer replace them. With each passing day, the ship’s inactivity was a growing source of frustration. By the time our customer came to us, they needed a solution, and they needed it fast.
But as the saying goes: ‘It’s always in the last place you look.’
Delivering the engine couplings in just eight weeks from our customer’s initial enquiry, Walker Rubber put an end to their year-long search, and ultimately, delivered on what mattered: getting the boat back in the water!
Dive in to find out how we did it.
Who is the customer and what did they require?
Our customer is a leading provider of services and solutions to the global marine industry. They specialise in managing maritime assets with enhanced efficiency, ensuring compliance and minimising risk using cutting-edge digital systems: from ship management and technical support to crew management and logistics.
They came to us in need of ten new engine couplings, whose rubber had completely deteriorated, rendering them ineffective and forcing the boat out of action. After 12 months out the water, and with a frustrating experience with a supplier under their belt, our customer wanted a solution that met their needs as soon as possible.
(Reverse) engineering the solution
1. Understanding the Problem
After receiving contact from the customer, we first prioritised understanding exactly what they needed. Examining photos and one of the old couplings they sent us, we assessed whether we could provide a solution, and if so, how we’d do it.
2. Reverse engineering the replacement parts
Using the old coupling as a reference, our team started to draught up drawings of replacement and the custom tooling required for both extruding the material blanks and moulding the parts themselves.
3. Refurbishing the metal housing
It became clear that not only all the rubber needed replacing, but the metal housing needed refurbishment, and, in the case of some of the parts, completely remanufacturing. We enlisted the help of one of our trusted partners specialising in metal fabrication to recondition and remake where required.
4. Testing for size
After we received the finished metal parts from our supplier, we could test fit all the metal parts into the mould, along with the rubber extrusion blank to ensure it would all fit together and work as we had hoped. Having custom tooling capabilities in-house means we could test and readjust the size of the profile and associated tooling quickly where required.
5. Moulding and shipping the finished mounts
With all the tooling ready, it was time for the final production. The new rubber extrusions were manufactured and then moulded into the housings using a hydraulic press to heat and compress each section to secure them in the housing. The excess material was trimmed away from the housings and the parts completed.
The result: a ship restored
Despite the challenges faced during this project, we are thrilled that our customer can finally return their vessel to the water where it belongs.
Given the severe wear and damage to the old engine mounts, designing the new parts to precise measurements was no small feat. This was undoubtedly a highly specialised, one-off job that many suppliers would have hesitated to take on.
However, it’s exactly this level of challenge and our positive, proactive approach to problems that bring customers to Walker Rubber; we take immense pride in delivering solutions where others can’t – or won’t!
A standout achievement in this project was the turnaround time. In just eight weeks, we managed to manufacture bespoke tooling, source refurbished or newly made metal housings, extrude and mould the new rubber parts, and deliver them ready for installation.
Our customer was so impressed by our work that we are already anticipating the arrival of the next set of couplings to refurbish!
Got a problem project? We have the solution
We understand the frustration when suppliers turn away your request because the solution to your problem is too complex, technical, or bespoke.
If you’re facing a challenge that requires expert attention, accuracy and speed, don’t hesitate to contact us today.
We look forward to hearing from you!