Precision Under Pressure: Inside the Die Shop Advantage at Essex Solutions

On the Fort Wayne campus of Essex Solutions, the work happening behind the doors of the Tool and Die Shop is measured in microns, though its impact is felt across the organization’s global manufacturing network. 

Led by Engineering Manager Jason Thackrey, the shop serves as both a cornerstone of the company’s vertical integration strategy and a competitive advantage that operates largely out of view. 

At its core, the department exists to support manufacturing operations with precision tooling delivered on timelines that enable continuity across production systems. 

“The biggest advantage to us is time,” Thackrey said. “Whereas it could take six to eight weeks to get an order from an outside vendor, we could do it in six to eight hours if we have to.” 

That responsiveness is more than convenience. It is a capability that allows production to remain stable, supports rapid problem-solving, and reduces disruption when urgent needs arise. 

Speed, however, is only part of the equation. The defining characteristic of the die shop is precision. 

“We’re bound to microns,” Thackrey said. “The average human hair is about 100 microns. We’re trying to hold plus or minus two microns.” 

That level of accuracy is essential in the production of enameled wire, where each die applies a controlled layer of coating that must remain consistent from start to finish. 

“There may be four to seven microns between dies,” Thackrey explained. “Each one puts a layer on, so it has to be right every time.” 

The result is a process where even the smallest deviation can influence product performance. Sustaining that consistency requires advanced equipment and a highly skilled team, but within Essex Solutions, it has become the baseline. 

“I honestly think it’s more expected than anything,” Thackrey said. “When other teams send us their order, they know what they will be getting back; the only question, really, anymore, is when.” 

That expectation reflects years of reliable execution, where precision and turnaround have become deeply embedded in how internal teams operate together. 

While standard production forms the backbone of the shop’s output, a significant portion of its value lies in customization and innovation. Roughly one-third of the workload involves custom machining, prototyping, and specialized requests from across the organization. 

“People come to us and say, ‘Hey, can you make this?’” Thackrey said. “If they go to a machine shop outside of here, it’s going to take them a long time and they’re going to have limited visibility into the process.” 

In many cases, internal capabilities allow teams to move directly from concept to execution while maintaining full control over design intent and technical requirements. “That technology stays in-house,” he noted. 

That control is a key advantage. By keeping tooling design and production internal, technical knowledge and proprietary processes remain protected. In a competitive manufacturing environment, that level of confidentiality carries weight alongside speed and precision. 

The integration of these capabilities strengthens the broader manufacturing model. Engineering, production, and innovation are closely aligned, reducing reliance on external suppliers and creating a more agile and resilient system. 

For Thackrey, the work is as much about problem solving as it is about production. 

“It’s all about how to shoehorn everything into it,” he said. “Figuring out the projects is one thing, but getting out and actually working on the stuff, that’s the fun part.” 

That balance between routine execution and hands-on innovation defines the culture inside the shop. Precision is nonnegotiable, but creativity remains essential to how challenges are solved. 

Inside the Tool and Die Shop, the margin for error is measured in microns, and the expectation is absolute consistency. The work may not always be visible, but its impact is embedded in every product that moves through the process and across the global network it supports. 

As Thackrey summarized it, “Our motto is that we are ‘Driven by Precision, Powered by Satisfaction.’ But the emphasis is certainly on the precision part!”