How Heartland Stairways Avoided a 6-Week CNC Router Breakdown

When the backbone of production is your CNC router and you can’t afford long downtimes, unreliable support, or equipment failure. 

That was the reality facing Heartland Stairways, a high-end Amish stair manufacturer and active member of the Stairbuilder and Manufacturers Association. Their C.R. Onsrud CNC router, critical to daily their operations, began to show signs of failure. No longer supported by the OEM, they sought a solution for a long-term fix that would keep production running smoothly for years to come.

A Shop with No Time to Lose

Heartland Stairways had invested in their C.R. Onsrud 193G18 Router back in 2007. At the time, the OEM provided strong support and the machine helped them modernize their operation with CNC technology. After the first five years, support started to fade. The shop foreman shared that any calls for assistance by Heartland left them feeling  like a burden rather than a customer. The threat of a CNC router breakdown became a real problem. Replacement parts became harder to find, repairs became a more frequent task, and when issues came up the only answer offered was: “Maybe it’s time to buy a new machine.”

But for Heartland, replacing the router wasn’t just costly, it was nearly impossible. The machine was cornered into a tight spot on the shop floor. This meant moving it would require days of disruption for their production. Also, the timeline for a new install was too long at 4-6 weeks for the installation of the new machine in addition to potential shipping delays and unforeseen costs along the way. With loyal customers relying on their full production schedule, extended downtime simply was not an option.

Stepping Forward With the Right Partner

It was around this time that Wes, one of MachMotion’s Solutions Partners, introduced them to the idea of a CNC control retrofit. Instead of buying a whole new machine, they could upgrade their old B&R control system to modernize the electrical components of their machine while keeping the sturdy, reliable frame.

After meeting with MachMotion’s team, company president Roy Hochstetler and the shop foreman felt confident. What stood out most wasn’t just the product, it was the process. They said it was a “no brainer” for them to go with us because of many reasons including:

• Only a one-week installation timeline
• Dedicated install team on-site
• Not having to move the machine
• Transparent pricing
• Modern control interface that felt intuitive from day one
  

The Installation Week

From day one, the MachMotion team communicated each step of the install with clarity and confidence. Throughout the week, the install crew stayed engaged, answering questions and ensuring the shop could plan around the work. Upon completion their upgraded control delivered a smoother, quieter machine with faster setup, cleaner cuts, and an easier user interface. On the final day of tuning, it was clear: their trusted CNC didn’t just run again, it felt brand new.

Long-Term Confidence

When Roy asked if MachMotion worked on other types of machines, it was clear the experience left a strong impression. Now, they have decided to upgrade an additional CNC router at their facility! The shop has already referred MachMotion to other businesses in the region, knowing firsthand how difficult it can be to find a responsive and capable partner in the CNC world. The Heartland team knows that when something comes up, they can get on the phone with MachMotion for real-time support.. With lifetime U.S.-based remote support, Heartland can have any issue addressed quickly to keep stairway production on track.

A Real Fix for Real CNC Router Breakdowns

Heartland Stairways didn’t just avoid a costly CNC router breakdown, they avoided weeks of downtime, massive shop disruption, and the uncertainty that comes with shipping a whole new machine out to only hope for the best. By choosing a MachMotion CNC control upgrade they took control of their shop’s future, protected their production, and doubled the life of their CNC router.

If your shop is patching problems, dealing with long support wait times, or struggling to justify a full machine replacement, you now know there’s a better way. Talk to our team at MachMotion to see how a control retrofit can double the life of your CNC machines without the downtime, cost, or hassle of buying new.