Emergency Gearbox Conversion Saves 14 Hours of Downtime
Amazon BHX2
14 hours
Downtime Saved
£587,000
Cost Savings
Resolved in 14 hours vs. OEM 16-week lead time
Timeline
The Problem
Critical Main Sorter Failure
At 3:47 AM on a peak demand day, the main sortation line gearbox at BHX2 suffered a catastrophic bearing failure. The OEM part (SEW F47 DRE90L4) had a quoted lead time of 16 weeks with significant import duties from Germany.
Impact:
- Main sorter completely offline
- Peak season disruption
- Estimated £42,000/hour in lost throughput
- OEM lead time: 16 weeks
- Import duty: £3,200
The Solution
Immediate Howcroft Response
Howcroft's emergency team arrived on-site within 2.5 hours. After assessment, we identified a compatible helical gearbox conversion (Howcroft Helical F47 - 1.5kW) with matching mounting dimensions and output shaft specifications.
Actions Taken:
- On-site technical assessment within 2.5 hours
- Compatible Howcroft alternative identified from stock
- Unit delivered from Midlands hub by 11:00 AM
- Installation support provided
- Line operational by 5:45 PM same day
Products Used:
Visual Comparison
Before & After Impact
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The Results
Measurable Impact
"Howcroft didn't just supply a part — they solved our problem. Their team understood the urgency, had the stock depth to deliver immediately, and provided the technical expertise to ensure compatibility. 14 hours of downtime during peak season could have been catastrophic. Instead, we were back online the same day."
James Mitchell
Senior Engineering Manager
Amazon BHX2