In forging and forming operations, downtime isn’t just inconvenient — it’s expensive. Whether you’re overseeing production schedules, managing maintenance teams, or handling procurement, you know the stakes. Every minute of lost production means missed delivery commitments, higher costs, and potential customer dissatisfaction.
For many manufacturers, the problem isn’t finding a replacement part — it’s getting the right OEM part fast enough to keep machines running. Lead times for specialty forging equipment parts can stretch into weeks, especially for older machines. In high-demand industries like automotive, aerospace, construction, and mining, those delays are unacceptable.
That’s where ACE (Ajax/CECO/Erie Press) steps in with our Parts Stocking Program — a proactive, cost-effective way to ensure your most critical components are ready when you need them.
The Hidden Economics of Downtime in Forging Operations
In the forging and forming industry, downtime is rarely a single-line expense — it’s a chain reaction that touches nearly every facet of an operation. When a critical machine stops unexpectedly, the costs extend far beyond the repair invoice:
- Production output drops to zero, creating backlogs that ripple through the supply chain.
- Labor costs climb as crews remain on the clock but unable to produce.
- Customer deliveries are delayed, impacting contracts, relationships, and future orders.
For some high-output facilities, even a single day of unplanned downtime can translate into tens of thousands of dollars in lost revenue, not including the long-term opportunity cost of disrupted schedules.
The problem is compounded by the way many replacement parts are sourced. Traditional ordering models rely on a reactive approach: parts are purchased only after a failure occurs. This triggers manufacturing lead times — often measured in weeks — during which equipment sits idle. In an effort to close the gap, companies resort to expedited freight, adding thousands in unplanned logistics costs.
Some facilities attempt to solve the problem with on-site spare parts storage, but that solution has its own economic trade-offs:
- Capital is tied up in inventory that may not be used for months or even years.
- Floor space is consumed by shelves and storage that could otherwise support production.
- Inventory management demands staff time to track, maintain, and periodically replace aging parts.
The ACE Parts Stocking Program offers an alternative. By pre-manufacturing your critical components and storing them at ACE facilities, we deliver guaranteed availability, immediate shipment, and OEM-certified accuracy — without the financial and spatial burdens of in-house inventory.
How the ACE Parts Stocking Program Works
Downtime in forging and forming isn’t just a matter of lost hours — it’s a direct hit to production capacity, profitability, and customer satisfaction. The ACE Parts Stocking Program is designed to eliminate the delays caused by long lead times and unpredictable supply chains, while removing the financial burden of maintaining your own spare parts inventory.
This is not a one-size-fits-all offering. Every forging operation has unique equipment configurations, wear patterns, and production demands. That’s why our program is custom-built around your operation, ensuring the parts you need most are always ready for immediate shipment — without tying up capital or floor space.
Here’s how we make that happen:
Custom Stock Planning
We begin by reviewing your equipment history, usage patterns, and maintenance records to determine which parts are most likely to require replacement. This could include forging press parts, hammer components, bearings, seals, and other wear items essential to your operation.
No-Cost Stocking
Once we’ve identified your priority parts, we manufacture them to original OEM specifications and store them in ACE’s facility. You don’t pay for them until they’re shipped, so your capital isn’t tied up in unused inventory.
Rapid Delivery
When a breakdown happens, your part is already built, inspected, and ready to go. Many orders ship the same day they’re requested — cutting downtime from weeks to hours.
OEM Precision
Because ACE is the original equipment manufacturer for Ajax, Chambersburg, and Erie Press machines, we have your original drawings, materials, and tolerances. Every stocked part is guaranteed to fit and perform exactly as intended, maintaining the safety, performance, and lifespan of your equipment.
More Than Just Parts — A Competitive Advantage
In today’s competitive manufacturing environment, the difference between meeting a deadline and missing it often comes down to how quickly you can get the right replacement part. The ACE Parts Stocking Program is not simply about storing components — it’s about building operational resilience into your business. By having your most critical OEM parts pre-manufactured and ready for immediate shipment, you gain an advantage that extends far beyond the storeroom.
With this program, you can:
Keep production schedules on track without costly, reputation-damaging delays.
Avoid unnecessary expenses from rush shipping fees and overtime labor costs.
Maximize valuable floor space for production rather than storage racks.
Operate with confidence knowing downtime can be measured in hours instead of weeks.
For high-volume operations, facilities running legacy equipment, and plants with strict delivery timelines, this isn’t just a maintenance solution — it’s a strategic safeguard that protects profitability, customer trust, and long-term competitiveness. It allows you to shift from reacting to equipment failures to proactively controlling how they impact your business.
Real-World Results
One ACE customer faced repeated delays waiting for critical press components. After joining the Parts Stocking Program, they reduced replacement lead times from several weeks to just hours. This meant zero missed shipments, no costly rush orders, and smooth production flow — even during unplanned maintenance events.
Read the full case study: How ACE’s Stocking Program Saved a Customer from Lost Production Time.
The OEM Advantage
With over 150 years of combined expertise from Ajax, Chambersburg, and Erie Press, ACE is uniquely positioned to support your operation. As the OEM, we build parts to exact original specifications, understand the operational demands of your equipment, and can anticipate your needs based on decades of industry experience. This depth of knowledge translates into better reliability, longer machine life, and reduced maintenance headaches.
Why the Program Works
The success of the ACE Parts Stocking Program comes down to its ability to address the three challenges that most often disrupt forging and forming operations:
Availability – Your most critical OEM parts are already manufactured, stocked, and ready before you need them — eliminating the uncertainty of long lead times.
Speed – With immediate shipping, downtime is reduced from weeks to hours, helping you keep production commitments and protect revenue.
Accuracy – Every stocked component is built to original OEM specifications, ensuring a perfect fit, optimal performance, and full equipment compatibility.
This formula doesn’t just solve maintenance problems — it transforms the way you manage equipment reliability. By combining readiness, rapid response, and precision manufacturing, the program gives you a dependable safety net that keeps your operation on schedule, your costs under control, and your customers confident in your ability to deliver.
Secure Your Uptime
Every day without a stocking plan is a day you’re taking a risk with your production schedule. ACE’s Parts Stocking Program gives you the confidence of knowing your most important components are just a phone call away — built to spec, in stock, and ready to ship.
📞 Contact us today to create your custom no-cost stocking plan.