From Labor Shortages to Longer Runs: How NKM Scaled with Robots
Facing labor shortages, NKM partnered with Gosiger Automation Within Reach and FANUC to deploy robots, boosting throughput, utilization, and growth.
Challenges
- Chronic labor shortage
- Production-constraining capacity limits
- Unfamiliarity with new technology and automation
Results
Increased capacity and scalability for longer run jobs
Faster production and fewer defects
Faster production and fewer defects
Seamless integration and strong service support
Story
Northern Kentucky Machine (NKM) in Boone County operates as a flexible job shop, handling everything from prototypes to large production runs for small and big companies alike. Faced with a tight labor market and the need to scale without sacrificing quality, NKM evaluated automation as a practical alternative to hiring for every incremental capacity need. Yet while leadership recognized that robots could act as an “extra person” on the floor—especially valuable for larger runs that benefit from longer, unattended cycles—hesitation existed.
“Nobody in this facility had ever run or touched a robot,” explained NKM Vice President of Operations Joe Sterling.
Yet despite the initial hesitation, the team adapted quickly with integrator Automation Within Reach (or AWR, formerly Gosiger Automation) managing installation and commissioning. AWR’s “RC-2” CNC machine tending system, powered by FANUC M-20 Series industrial robots, integrated easily into the workflow, ensuring optimal efficiency and precision. AWR’s turnkey approach—delivering on site setup, programming, and training—removed much of the uncertainty around new technology.
In short order, operators learned to program and run the cells, and the shop began routing longer “lights-out” runs to the robotic stations while reserving shorter, quick change jobs for conventional equipment.
Today, workers have been freed up to focus on higher skill tasks. Early operational data show faster cycle times and more consistent part quality; as NKM continues to collect and analyze performance metrics, the company expects measurable reductions in defects and further productivity gains.
With automation proving its value, the company plans to scale robotic use for additional long run work, further increase capacity and expand service offerings.
As we continue to integrate the RC-2 robots into our operations, we expect to see measurable improvements in production speed and reduction in defects contributing to a greater overall efficiency. It’s awesome. It’s helping us make a leap forward, and I don’t want anybody else to have it.
Joe Sterling Vice President Operations – NKMFANUC Products Used
M-20iD/25
The FANUC M‑20iD/25 is a compact 6‑axis robot ideal for machine loading and unloading, parts handling and precise positioning in crowded factory environments.
- Max Payload:
- 25 kg
- Reach:
- 1831 mm
Meet Automation Within Reach, FANUC Authorized System Integrator
Automation Within Reach (AWR) transforms manufacturing operations through proven machine tending automation solutions that eliminate production bottlenecks and deliver measurable results from day one. Since 2018, we've engineered accessible CNC machine tending systems for manufacturers across all scales—from emerging operations to established production facilities. AWR strategically expanded in 2025 to include custom automation, integrating over 30 years of Gosiger Automation's proven expertise to provide a comprehensive range of solutions.
We understand that successful automation requires more than equipment selection—it demands manufacturing intelligence, strategic industry partnerships, and strategic execution that aligns with operational realities. Whether implementing your first automated system or expanding existing capabilities, AWR delivers the technical expertise and comprehensive support that transforms automation investments into lasting competitive advantages.
About Northern Kentucky Machine
Since 1989, customers have turned to Florence-based Northern Kentucky Machine, or NKM, to provide competitive pricing on CNC machining services and quick turnaround times to meet their manufacturing needs. From 5-axis machining to welding and fabricating, our 15,000-square-foot facility has the capacity and technology to meet the needs of both small and large enterprises.
