B&W Trailer Hitches: A Story of Growth Through Automation

01

The Beginning

The B&W story begins in 1987 in Humboldt, Kansas, when Roger Baker and Joe Works joined forces to provide for their families.

With Baker's classic car restoration skills diminishing in demand and Works facing tough years on the family farm, they began applying their craftsmanship to building custom truck beds under the name B&W. What started as necessity soon led to innovation when they recognized a common problem with gooseneck hitches.

They designed the revolutionary Turnoverball Gooseneck Hitch—featuring mounting hardware underneath the bed and a ball that turned over and stowed in place. This ingenious solution transformed the industry, with nearly every gooseneck manufacturer today using this type of ball storage and mounting system.

From these humble beginnings, B&W has grown into a 647,000 square foot manufacturing powerhouse, building some of America's most trusted towing products. Their journey from small shop to industry leader wasn't just about expansion—it was about maintaining the same level of quality and craftsmanship at scale.

"It all starts with Joe Works and his vision. The culture that we have here is an extension of Joe's beliefs. We do everything to emulate that in every decision and how we function. And really, that's the root of the success." ~ Shane Wolverton, Production Manager, B&W Trailer Hitches

35+

Years of Excellence

647k

Square Foot Facility

25+

Years with Miller

02

The Challenge

As demand for B&W products grew, the company faced a critical question: How could they dramatically increase production while maintaining their exacting quality standards?

B&W's reputation had been built on precision and reliability. Their customers—from commercial haulers to weekend camping enthusiasts—trusted B&W Trailer Hitches to securely tow heavy loads. There was no margin for error or inconsistency.

For a company based in rural Kansas, finding enough skilled welders to support rapid expansion presented another significant challenge. The traditional approach of scaling through additional manual welding stations would be difficult, if not impossible, to sustain.

Perhaps most importantly, B&W needed to maintain their commitment to American manufacturing. Outsourcing wasn't an option—they needed to find a way to dramatically increase productivity in their Humboldt facility.

"A lot of people worry about automation taking away positions and jobs. But from my experience, the shops that go with automation end up having to hire more people because they are doing higher quality work." ~ Jeremy Ivey, Supervisor Robotic Welding, B&W Trailer Hitches

Increasing Demand

Growing market share required significant production increases

Quality Standards

No compromises on the precision and reliability of their products

Skilled Labor

Limited skilled welding workforce in rural Kansas

03

The Solution

B&W found their answer in Miller's PerformArc robotic welding systems—technology that would transform their manufacturing capabilities while preserving their quality standards.

Starting with 16 PerformArc cells, B&W began a carefully planned integration of automation into their manufacturing processes. These weren't replacements for skilled workers but tools to enhance their capabilities and focus their expertise where it mattered most.

What began as a capability-expanding investment became a true partnership. As B&W grew, Miller worked alongside them, continuously improving the PerformArc systems to meet evolving needs. Their growth trajectories aligned perfectly, with each company developing and innovating in tandem.

When standard solutions weren't enough, the partnership became even more valuable. B&W's engineering team collaborated with Miller to develop custom solutions, including creative retrofits that added secondary robotic arms to existing cells—dramatically increasing throughput without requiring entirely new systems.

"As much as I think that I can weld something and be as smooth and consistent as an automated robot—that's a joke. I am nowhere near a robot. The automation process is very, very fluid, very smooth, and can produce repeatable welds day in and day out." Chad Klauman, Qaulity Asurance, B&W Trailer Hitches

Precision & Repeatability

Consistent, high-quality welds on every product

Ease of Programming

User-friendly interface that operators quickly mastered

Adaptable Design

Flexible systems that could be customized and upgraded

04

The Results

The integration of Miller PerformArc systems enabled B&W to achieve remarkable growth while enhancing product quality and consistency.

With the precision and repeatability of the PerformArc systems, B&W ensures every weld meets their strict quality requirements. Their Certified Welding Inspectors validate the consistency of these automated processes through regular testing and documentation.

Rather than reducing employment, automation has enabled B&W to grow their operation significantly, creating new jobs and opportunities in their community. They've been able to train operators without extensive welding backgrounds, expanding their workforce beyond the limited pool of skilled manual welders in the region.

The durability of the PerformArc systems has also provided exceptional return on investment. Some units have been in continuous operation for nearly 20 years, while still maintaining the precision required for B&W's quality standards.

"What I appreciate most about Miller's PerformArc welding units and welding automation with PerformArc, it's a really plug and play ready to go process. And with us having numerous of machines that definitely stands that foundation where we can say we can put that next part on there, we're ready for production." ~ Michael Young, Production Supervisor, B&W Trailer Hitches

30%

Reduction in production cycle times

20+

Years of reliable performance from original systems

100%

Consistent weld quality across all products

05

The Future

The partnership between B&W Trailer Hitches and Miller Electric continues to thrive, with both companies committed to innovation and excellence.

As B&W looks to the future, they're exploring new ways to leverage automation and robotics in their manufacturing processes. They continue to work closely with Miller to identify opportunities for improved efficiency, quality, and productivity.

This collaboration showcases the power of true partnership—where a supplier becomes more than just a vendor, but a collaborative ally in achieving manufacturing excellence. Miller's commitment to supporting B&W's growth has created value that extends far beyond the initial equipment sale.

For manufacturers facing similar challenges, the B&W story demonstrates that with the right technology partner, it's possible to dramatically scale production while enhancing quality and creating new opportunities for skilled workers.

"From a Miller perspective, I think we've approached this relationship with humility and with a problem-solving mindset from the beginning. Whether that was developing automated welding cells to help enhance productivity and drive throughput on the manufacturing floor, or improving processes for consistency in their welding operations—in either event, it was with an aspirational mindset of adding value and being a partner that would add value every day and not just a supplier that would have value when we made a sale." ~ Dave Lambert, Group President, Miller Electric

The B&W Trailer Hitches Story

From Garage to Industry Leader: How Automation Fueled Remarkable Growth