Design and Manufacturing

BY PUSHING THROUGH PERCEIVED LIMITS, GRAYHILL EXCEEDS OUR CUSTOMERS' EXPECTATIONS AS WELL AS OUR OWN.

Grayhill is passionate about seamlessly meeting our commitments to those who trust us to deliver quality and innovation. We broaden the success of our customers and who they serve by enabling them to perform at a higher level. The Grayhill design, manufacturing, and support process consistently delivers an unparalleled class of services and custom-engineered product offerings.

Our engineers start with a deep understanding of the technology, haptics, ergonomics, and styling our customers expect. A key strength developed by our decades of experience is the ability to construct a turnkey solution that best suits each customer’s specifications. We are highly attuned to the evolving needs of end-product users in our target markets: medical electronic devices, military applications, and off-highway vehicles.

Design and Manufacturing

DESIGN

Our customers’ projects benefit from our knowledge of the latest technologies and insight from our R&D investment in award-winning standard operator interface products.

Grayhill’s in-house design expertise includes the following disciplines: industrial design, ergonomics, mechanical engineering, electrical engineering, software engineering, test engineering, manufacturing engineering, supplier quality engineering, process quality engineering, and reliability engineering.

We use the following design and simulation tools: Rhino for industrial design, Pro/Engineer 3D modeling, Mentor Graphics DxDesigner, Mentor Graphics PADS: PCB layout, National Instruments Labview, Hertzler QAS, ViewPart, and a secure FTP site for sharing project schedule, design details, FMEA results, issues list, and qualification test results.

PLANNING

Our commodity managers, purchasers, and planners use our enterprise SAP system and Electronic Data Interchange (EDI) to accurately forecast, plan, purchase, and tool for manufacturing and product lifecycle management.

By strategically investing in people and equipment and leveraging relationships with key suppliers, Grayhill has honed an ability to produce prototype components and assemblies faster than the competition.

To meet unique project requirements, Grayhill constructs a design and manufacturing plan optimally suited to each customer’s specifications. A series of highly flexible production cells provide the backdrop for a seamless transition from prototype to initial production. Critical procedures and software are shared across all facilities, allowing us to quickly scale up or move production to another location with minimal risk.

We will design a supply chain for your product to minimize cost and risk of interruption. Once the product is in production, we are well-versed in logistics and will devise the right strategy for you.

MANUFACTURING

We bring custom products to market faster and stay on your critical path by utilizing in-house molding, tooling, testing, and manufacturing capabilities. Grayhill also has the flexibility to manufacture in the U.S. and Asia to support your global distribution needs.

We make continuous investments in state-of-the-art machinery and robotics. Our vertically integrated production facilities allow Grayhill to meet all your production needs.

Our specialty is molding precision piece parts for various Grayhill products. Our Iola, Wisconsin, facility has supplied high-quality plastic components and assemblies to Grayhill, Inc., La Grange, for over two decades.

Grayhill Iola also has thermoplastic reciprocating screw injection molding machines, including state-of-the-art computer-controlled presses. These presses can accommodate sprue or parting-line injection insert molding jobs. In addition, our small Arburgs are dedicated primarily to two-shot molding projects. We can mold shot sizes up to three ounces with clamping forces ranging from seven to 83 tons. Much of our production involves the use of high-temperature engineering resins.

Our fully-equipped toolroom enables us to design and build new tooling and maintain existing molds. ISO 9001 certified, Grayhill manufactures to industry and military standards to assure quality and reliability.

TESTING AND QUALITY

Quality is crucial to every project, starting at the initial conceptual stages. Our origin as a manufacturer for the U.S. military means that Grayhill’s quality has always had to be of the highest integrity. We maintain REACH and RoHS-compliant standards in a frequently changing landscape.

An Advanced Product Quality Planning (APQP) procedure controls our stage-gate development process. Numerous reviews are performed during the project, including design and process FMEAs. Testing is integrated into each step of our manufacturing processes. All custom-tooled piece parts in your assembly require an approved Level 3 PPAP analysis.

For more detailed information about our testing procedures, please see our Quality and Quality Testing pages.

PRODUCT SUPPORT

When you begin the design process with Grayhill, you can feel confident knowing that through our Customer Corrective Action (CCA) process and service hub, we take responsibility for the life of your product, including field issues and warranty.

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YY= WE CUSTOMIZE DOWN TO THE SMALLEST DETAIL. WHAT IS YOUR X?

Grayhill has extensive experience developing, tooling, and producing Custom Operator Interface products. We are committed to your product from design through support. Let Grayhill take your project from concept to reality. Contact us to begin.