From Labor Shortages to Longer Runs: How NKM Scaled with Robots

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.

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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 – NKM