Manufacturing Today - January/February 2016 - 69

Cosmos Manufacturing Inc.

	 The	power	unit	is	made	of	an	aluminum	 casting	 designed	 and	 manufactured	by	Cosmos	in	collaboration	with	
RGC.	 The	 company	 has	 rigorously	
tested	the	power	unit	to	ensure	it	can	
withstand	 harsh	 conditions.	 In	 addition	to	being	durable,	Cosmos	also	designed	 the	 MaxCutâ„¢	 chainsaw	 to	 be	
easy	to	use.	
	 "We've	tried	to	develop	an	ergonomic	power	unit	that	is	easy	to	handle,"	he	
adds.	 "We	 want	 to	 alleviate	 stress	 on	
the	operator."
	 The	 company's	 World	 of	 Concrete	
exhibit	 and	 other	 marketing	 efforts	
will	emphasize	the	optimum	use	of	the	
chainsaw.	 "We	 want	 consumers	 and	
other	users	to	get	the	best	results	possible	from	our	products,"	Michelon	says.

Staying Steady
The	 MaxCutâ„¢	 product	 line	 and	 Cosmos'	other	manufactured	components	
reflect	the	company's	commitment	to	
help	its	customers	solve	difficult	problems.	"We	never	chase	easy	jobs,"	Michelon	says.
	 Cosmos'	research	and	development	
team	 works	 with	 customers	 to	 bring	
ideas	from	rough	concepts	to	fully	designed	 and	 manufactured	 products.	
"Our	 goal	 is	 to	 provide	 our	 customers	 with	 more	 than	 they	 expect,"	 the	
company	says.	"We	welcome	customer	
concepts	as	a	starting	point	and	enjoy	
the	 challenge	 of	 expanding	 on	 those	
ideas	to	develop	products	to	fit	within	
the	constraints	provided."
	 Products	 are	 manufactured	 in	 a	
100,000-square-foot	 facility	 that	
houses	 a	 vast	 array	 of	 tooling	 and	
equipment.	 The	 company's	 manufacturing	 processes	 include	 progressive	
stamping,	 spot	 welding,	 manual	 and	
robotic	 MIG	 welding,	 laser	 welding,	
automated	assembly,	copper	and	nickel	 furnace	 brazing,	 crimping,	 deburring	and	tube	cutting.

Midwest

"our goal is to pro-	
vide our customers
with more than they
expect. We welcome
customer concepts as
a starting point and
enjoy the challenge
of expanding on those
ideas" - John Michelon
Cosmos	 utilizes	 automation	 as	 well	
as	 Six	 Sigma	 and	 lean	 manufacturing	
principles	 to	 manufacture	 products	
in	a	highly	efficient	manner.	The	company	 produces	 more	 than	 10	 million	
mufflers	 a	 year	 for	 lawn	 and	 garden	
OEMs	 in	more	than	100	different	designs,	it	notes.	
	 All	 of	 the	 company's	 products	 are	
tested	in-house.	
	 "Our	 in-house	 test	 labs	 provide	 us	
with	the	ability	to	thoroughly	evaluate	
the	 products	 we	 make,"	 the	 company	
says.	"We	can	test	various	types	of	engines	and	equipment	over	a	wide	range	
of	test	cycles."
	 The	 company's	 testing	 services	 include	 emissions	 testing,	 bench	 aging,	
catalyst	conversion	efficiency,	thermal	
imaging,	sound	analysis	and	vibration	
testing.	 In	 addition	 to	 testing	 its	 own	
products,	the	company	also	offers	contract	testing	services	to	customers.	
	 Cosmos'	 commitment	 to	 quality,	
competitive	 pricing	 and	 long-term	
customer	 and	 vendor	 relationships	
have	helped	it	navigate	through	a	number	 of	 economic	 and	 market	 changes	
throughout	its	history.	
	 "We've	 never	 had	 to	 do	 a	 massive	
layoff	here,"	Michelon	says,	noting	the	
company	is	proud	that	its	products	are	
engineered	and	manufactured	entirely	
in	the	United	States.	"We've	been	able	
to	 ride	 out	 the	 economy	 without	 having	an	impact	on	employees."	mt
JANUARY/FEBRUARY 2016		 manufacturing-today.com			69


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Table of Contents for the Digital Edition of Manufacturing Today - January/February 2016

Contents
Manufacturing Today - January/February 2016 - Cover1
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