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The History of Fadal Engineering

By Larry de Caussin

O ur father, Francis de
Caussin was a toolmaker
trained in the automobile in-
machine shop to work at it full
time. The problem was the
new business had to be started
dustry. Francis moved the and sustained with the $2000
family from Detroit Michigan cash we had on hand. We
to Van Nuys California in rented a 800 square foot in-
One of the company’s first logos.
1953. Francis always had a dustrial unit in North Holly-
dream to own his own ma- wood California. Along with
chine shop. Francis had a lot lathe. Eventually, we pur- the new workspace, we
of skills but not a lot of mon- chased an 11 inch Logan lathe bought a new Italian 12 inch
ey. But, this didn't stop him. with a bed turret and a very Siamp metal cutting lathe on
He purchased some equipment small metal cutting mill called dad's good credit for $3500.
on time payments. The first a Bench Master. The equip- Now, our equipment list con-
equipment he bought was a ment was purchased from sisted of two lathes, one very
Shop Smith mainly for wood- Montgomery & Wards, and small mill with riser block, a
work, but we used the Shop paid for by Gladys, on time Sears drill press, and a one
Smith's drill press for drilling payments of course. horsepower air compressor.
metal pieces. Francis brought We all learned a lot in our part With the little bit of cash on
machining work home from -time garage business. We all hand we had to start slowly.
the machine shop where he learned the faster and more So, only Francis and Larry,
worked. The plant manager efficient we removed the met- who still lived at home, quit
where Francis worked put a al in the manufacturing pro- their jobs and worked full-
metal cutting lathe in our fam- cess, the more money we time in the business. Gladys
ily garage. We had to pay him made. Even at that time, we set up the books, and it was
a percentage of any money began to customize the equip- only a matter of weeks before
earned from the use of his ment that we had purchased, David could come full-time,
lathe. This was about in the to improve its productivity. and another year or so before
year 1955. At this time, Fran- An example of this is when Adrian could come in.
cis' oldest son, Adrian, was Francis added a riser block to
married. David was still in our very small mill that al- We all worked very hard,
High School and Larry was in lowed us to take bigger jobs. Francis did the quoting and
Junior High School. Francis Another time, Larry added a ran a machine. David and
and David worked on the temporary second motor to the Larry did most of the machin-
lathe, and Larry worked on the main spindle of the lathe so ing. Adrian did some machin-
drill press. At this point, it was that we could take the metal ing along with some office
only part-time work. In the off faster when needed, and work. Gladys handled the
evenings and Saturdays Fran- Dave made the handles longer finances and office work. Un-
cis would work, and after so we could push harder. This fortunately, the business fell
schoolwork, David and Larry was the start of a very interest-
would put in some time. ing trend. The trend was to
In the year 1957, the name make a better and faster ma-
Fadal was taken for the newly chine.
forming company. Fadal is an
acronym made up of first let- By 1961, Francis, David, and
ters of the names of Francis de Larry were all working in the
Caussin and his three sons, same machine shop for a com-
Adrian, David, and Larry. The pany called Device Seals.
same year, our mother, And, Adrian was working in
Gladys, took a job at a mail- the aerospace industry. After
order desk. She did this to the all the part-time experi-
help us purchase our own ence in our garage shop, we
equipment as we were work- made an unanimous decision
ing at home on the borrowed that we should start our own Francis de Caussin, President of
Fadal Engineering
February 1975, Hughes Aircraft awards Fadal with the Zero Defect Award because of the outstanding work
performed on complex precision machined parts.

on hard times around 1965 or precision machining, and we agent advised us to sell the
1966. One of our largest cus- had in our job shop some of stock because the original
tomers went into chapter 11 the world's most skilled ma- $17,000 in stock had already
owing us about $17,000. Be- chinists. All the jobs we re- dropped to $10,000. We sold
cause of the hard times, Adri- ceived we were able to accom- the stock at a loss for $10,000,
an decided to do some con- plish with our talented crew. but at least we were fortunate
tract computer programming. Fadal delivered high quality to get the $10,000 because the
He became busy programming machining at competitive pric- stock within a few months
for Signal Oil and Gas, which es and excellent customer ser- went to zero. We decided to
eventually won him a job of- vice. Because of this, Francis put the regained money to
fer in the Oil Industry. Adrian and Gladys were called to good use. With the $10,000,
felt that it would be better for Washington to receive the we put a down payment on
the company and him to take small vendor of the year our own building at 7260 At-
the offer. We were all sad award, which was very pres- oll Avenue in North Holly-
because it took him and his tigious. In addition to this, wood California. From this
family far away to Texas. Fadal's job shop won many new location Fadal began to
quality awards from the air- grow. Eventually, at that
Meanwhile the shop began to craft industry. One award was North Hollywood location we
pickup, we were doing a lot of Hughes aircraft annual Suppli- leased one building after an-
work for the space projects er Zero Defects Award. other. From 1980 to 1992,
like the Surveyor unmanned eight other buildings were
landing on the moon, Voyag- In 1970, the bankruptcy debt leased and a parking lot. At
er, various satellites, aircraft owed to us from Summers our North Hollywood facility,
landing gear, and eventually Gyroscope was paid back in we had roughly 50,000 square
the Space Shuttle fuel sys- the form of the debtors stock. feet made up from nine differ-
tems. We would take any The chief executive officer of ent buildings. In 1993, we
work that would fit our ma- Summers Gyroscope advised moved into our Chatsworth
chines, and even some that us to hold onto the stock. We facility that had over 200,000
really didn't. All of this air- listened to the CEO and decid- square feet under one roof.
craft work in Southern Cali- ed to keep the stock. About This helped tremendously giv-
fornia required high-quality two weeks later, our insurance ing us room to expand and
work efficiently. VMC 40 machining cen- tools had to be changed using
ters a wrench by hand. We
Before we go into more histo- 1984 Fadal job shop closed. promptly designed a power
ry we need to clarify a rough 1993 Moved to Chatsworth draw bar, so that the tools
timeline of events. facility. could be taken in and out of
1995 Purchase of Fadal by the spindle without the use of
1955 Part-time machine work Giddings & Lewis a wrench. This made making
done in garage. 1995 Over 10,000 Fadal verti- tool changes much faster and
1957 Company name Fadal cal machining centers easier. This set us to thinking
was chosen sold worldwide, in 10 how we might automate the
1961 Fadal started a full-time years time. whole tool changer process.
operation doing contract We realized how valuable an
machine work. aftermarket tool changer
1963 First employees hired. The year 1969 was important would be to all the small ma-
1969 Purchased our first NC in Fadal's history. That year is chine tool builders and their
milling machine. when we bought our first nu- customers. Our goal was to
1972 Began developing after- merically controlled machine. manufacture an affordable
market tool changer. It was a Bridgeport mill with a tool changer that could be at-
1974 Took tool changer to Superior Electric N.C. control tached to a mill. Brother
market. and a Spindle Wizard third Dave was soon totally con-
1976 Began development of a axis. Our new NC cost sumed with the designed, and
complete machining $25,000, which at the time, manufacturing of a prototype.
center including CNC was about the same price of a In about a year, we had a sec-
control. three-bedroom home in San ond generation tool changer
1980 Sale of first VMC 45 Fernando Valley. This ma- that was essentially the me-
machining center. chine did not have an auto- chanical design used for the
1983 Design and sale of first 5 matic tool changer, all the finished product. We soon

On May 22, 1975, Larry and Elsie de Caussin are guests at Cape Canaveral in Florida to see the launching of
the Intelsat IV-A communications satellite. It was the first of six such satellites that would handle the demands
of telephone, data, and television transmissions between the United States, Europe and West Africa.
realized that we needed some
help with the electronics.
Adrian, which was still in
Texas working in the Oil in-
dustry, showed enthusiastic
interest in the project. Even
though he had no electronic
experience, he began working
on a logic board that could
control the tool changer. His
initial design was built on a
cookie sheet and hand carried
to California. We all decided
that it was time for Adrian to
return to the company full The first five VMC-45 in use in our machine shop.
time to help with this project. expensive control to go with Draw. The reason behind
In 1974, Adrian and his family it. We decided it was a good calling it Quick Draw was
packed up and left Texas to opportunity for us to build because it was “quick” at
return California. Adrian and operating capital. We negoti- drawing out a tool with its tool
David brought the mechanical ated a cash sale, and the rights changing arm, and a “bandit”
and the electrical together to to manufacture the mechanical because it would steal the
make a successful reliable tool assemblies. The deal was business away from the com-
changer. After some time, we made with Summit Engineer- petition. Summit engineering
decided to go to market with ing. They named the tool used the Bandit name for their
the new tool changer. The changer the Bandit Quick whole product line, which was
tool changer was very successful. We
mounted on a milling went on to produce
machine and then load- over 2000 of the me-
ed onto a flatbed truck. chanical assemblies
David and his wife Mert for the new owner.
drove it to the 1974 ma- The profits gained
chine tool show in Chi- from the tool changer
cago. The tool changer made it possible to
was a big hit at the Chi- start a new and bigger
cago show. They met project, the designing
many potential distribu- of a complete machin-
tors of our new product. ing center including
We went on to make the CNC control. The
about 100 of these tool CNC control was start-
changers, with the Fadal ed first. Adrian had a
name on them. Then a degree in mathematics,
Company named Sum- and had began pro-
mit Engineering, out of gramming computers
Bozeman Montana, a as early as 1955 for
division of Dana Corp. Rocketdyne a division
offered to buy the tool of Rockwell Interna-
changer design and pa- tional. The experience
tents. Summit engineer- Adrian had helped him
ing was new in the busi- have a clear picture of
ness of building CNC how the software, for
controls. They had vi- the CNC control,
sions of packaging our The Fadal VMC-45, less than 40 produced. The last should be laid out.
tool changer with a in- one sold in 1983 before the introduction to the smaller Francis and Larry con-
and lower cost VMC-40.
United States; if they did that
they had no limits. To sell
over the VRA limits, foreign
builders were required to have
a very high percentage of their
machine American made. The
VRA agreement lasted for
about 10 years starting in the
early 1980s. Now looking
back, we felt that the VRA
didn't help us that much, be-
7260 Atoll Avenue, North Hollywood, California, Fadal’s front office cause our product eventually
buildings in 1984. faced competition.
When machine tool prices
centrated on running the job profit. We sold 25 of our dropped in 1980, we could see
shop and manufacturing the VMC 45 machining centers that low prices were here to
tool changers for Summit En- for about $95,000. It took stay. In early 1983 it was time
gineering. This helped free about three years to sell the 25 to re-group. We learned that
Adrian and David to concen- machines. Fortunately, The there was strength in price,
trate on this massive project of U.S. government stepped in to and that we had to make a
designing, manufacturing and control the dumping of ma- complete machining center for
bringing to market a complete chine tools into the U.S. They half the price of our present
machining center. It took all did this because the dumping one, or get out of the machine
we had but by the end of 1979 was destroying the machine tool business. This seemingly
we were ready to go to mar- tool industry. The machine impossible task was complet-
ket. We had been using the tool industry is very important ed in less than nine months.
prototype-machining center, to national defense; therefore We were ready to go to mar-
which we called the Fadal something had to be done to ket with a new low cost ma-
VMC 45 in our shop to do protect the United States ma- chining center. In the last few
contract machining. We even- chine tool industry. Machine months of 1983, we sold the
tually had five VMC 45s in tools dumped in the
use in our job shop. David U.S. came mainly
sold the first VMC 45 machin- from the Pacific
ing center in early 1980. Un- Rim countries. All
fortunately, in the 1980s hard importers of ma-
times came on the economy chine tools came to
and especially the machine a "voluntary re-
tool industry. We had an ex- straint agreement"
cellent price for our machin- which was called
ing center, but when the hard the VRA agreement.
times came every other ma- Machine tool im-
chine tool, which sold for 40 porters agreed
percent more than ours sud- amongst themselves
denly, lowered their prices. A to limit how many
machine that had a price tag of machines each of
$160,000 was then selling for them would ship
less than $100,000. Foreign into the United
countries began dumping their States each month.
extra machine tools into the The only other op-
U.S. market making it difficult tion that foreign ma-
for American machine tool chine tool builders
builders to sell American had was to set up
made machining centers at a manufacturing in the The Fadal VMC-40, first sold in 1983 and was
the platform of all the Fadal models to come.
but the United States Federal
and State tax laws are very
anti-family business. In order
to transfer the company over
to the family, the partners of
Fadal would have had to pay
about a 55 percent gift tax,
based on the value of the com-
pany. All of Fadal's cash was
tied up in property, equip-
ment, inventory, and accounts
receivable. Therefore, the tax
was too large to borrow
Fall 1993, Fadal moves into this new 220,000 square foot manufactur- enough to cover it. The tax
ing facility located at 20701 Plummer St., Chatsworth, California. would have had to be paid out
of profits. Of which the prof-
first 5 machines. Everyone future of Fadal had to be dis- its are also taxed at approxi-
loved the price and the speed cussed. In a family business mately 50 percent. After pay-
of the machine; we could not estate planning is a must, in ing these two very high taxes
make them fast enough. Each 1990 we began a special effort 1 dollar earned would now be
year we sold more and more to plan how the partners of about 25 cents in the pocket.
machines. This was all possi- Fadal might retire, and the With this heavy outflow of
bly, thanks to the heavy con- possibilities of transferring the cash to cover the taxes, it was
tributions of all our family company to the family. We feared that it would make it
members, and the employees called in outside advisers to impossible for Fadal to grow
of Fadal. The company’s per- enlighten us of all the differ- and possibly could have
formance was unequaled in ent possibilities that were ours brought it to its demise. It
the machine tool industry. for the choosing. We would would have taken another life-
Before Fadal revolutionized have loved to transfer our in- time to make the transfer to
the way machining centers terests in Fadal to the family, the family. There are a num-
were made, there were some
machine tool builders that
built about one machining
center per employee each
year. Fadal, on the contrary,
was building 10 machining
centers per employee each
year. By 1995, we had sold
almost 10,000 machining cen-
ters.

It was a long process to go


from a machine shop based in
a family garage to the worlds
leading vertical machining
center manufacturer. The Fa-
dal family business was now
quite a manufacturing corpo-
ration. This large corporation
being owned by only the
founders of the company was This is a 1997 letter from John Ball of B&T Industrial Supply to Larry
now becoming an estate issue. de Caussin. He describes the relationship between his company and
Fadal as Fadal grew from a small shop scraping to get by to the leading
Decisions to determine the VMC manufacturer in the world.
Larry, David and Adrian de Caussin

ber of government-approved
methods of making the trans-
fer, but all they do is delay the
misery, and government still
want their taxes sooner or lat-
er. The option of taking the
company public just did not fit
what we wanted. So, after
much careful thought it was
decided that an outright sale
would be best. Therefore, Fa-
dal was sold to Giddings and
Lewis in April of 1995.

The de Caussin family gave


their complete confidence that
Giddings & Lewis
would continue to
maintain Fadal's
bright future.

Fadal is now part of a large corporation.

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