For more than a century and a half, Gleason has stood at the forefront of gear manufacturing, shaping not just machines and processes, but the very evolution of the global gear industry. Founded on engineering excellence and a deep understanding of customer needs, the company has continuously reinvented itself, embracing new technologies, markets, and manufacturing philosophies while staying true to its core values.

In this exclusive interview, John J. Perrotti, Chairman and Chief Executive Officer of Gleason Corporation, reflects on the company’s remarkable 160-year legacy and its journey into the future. From the development of the Design–Manufacture–Measure strategy and the Smart Loop Ecosystem, to addressing the demands of electrification, sustainability, and Industry 4.0, Perrotti offers insights into how Gleason balances tradition with transformation. He also shares his perspectives on leadership, global collaboration, and the opportunities that lie ahead for the next generation of engineers entering the gear and power transmission industry.

1. Gleason has been shaping the gear industry for over 160 years. How do you ensure that the company continues to innovate and stay ahead in a rapidly changing manufacturing landscape?

We will remain focused on people and process. The foundation of our company culture emphasises continuous learning and customer focus, accompanied by an unwavering passion for problem-solving and continuous improvement. We will continue to adapt to develop skill sets around digital manufacturing, automation and a systems approach across the entire value chain of Design – Manufacture – Measure.

John Perrotti, Chairman and Chief Executive Officer of Gleason Corporation, drives a Design – Manufacture – Measure strategy to build a Smart Loop Ecosystem.

1. Gleason’s concept of “Total Gear Solutions” and the Smart Loop Ecosystem connect design, manufacturing, and inspection digitally. How has this approach transformed the way your customers produce gears today?

We are in the early phases, but customers realise this connected value chain is the only means to meet the challenges for high productivity and high precision in a repeatable manner. The infrastructure we have built is robust and can be customised for our customers’ varying environments.

• The shift toward electrification and e-mobility is redefining transmission design. How is Gleason adapting its technology portfolio to meet the demands of EVs and future powertrains?

We have invested significantly across design, manufacturing and measurement processes to address the needs of these markets. This investment strategy includes Gleason’s KISSsoft gear design software with its advanced analysis tools and the KISSsoft System Module as well as every relevant gear manufacturing process including hobbing, chamfering, power skiving, grinding and honing and measurement solutions, analytical measuring machines with Advanced Waviness, GRSL, INTRA SFT and DFT single and double flank inspection systems providing stand-alone or up to 100% in-process quality assurance with smart tools to identify ghost orders and root causes, and finally a wealth of functional gage products, tailored to our customers’ requirements.

Gleason’s KISSsoft Gear Design Software and KISSsoft System Module offer the design and optimisation of single gears as well as complete transmission systems with many integrated and optional plugins for further analysis. KISSsoft is a central element of Gleason’s Smart Loop Ecosystem approach.

• With facilities and customers across multiple continents, how do you maintain a balance between global integration and local responsiveness, especially in key regions like India and Asia?

Gleason has been serving international markets since the late 1800’s, so we have had a great deal of experience working with many different cultures but maintaining alignment with our core principles and mission. One of the things I am most proud of is how our team spread across 19 different countries cooperates and collaborates on a daily basis. Common philosophical and moral values are an important foundation for consistent messaging and global leadership.

• Sustainability is now a central pillar of industrial strategy. How is Gleason embedding energy efficiency, waste reduction, and circular practices into its machines and processes?

Gleason has installed a global team of experts in relevant fields focussing on measuring and reducing our carbon footprint. As we develop new products and features, sustainability is one of the key areas we address. At the same time, we serve customers in important markets including electrification, wind power and other sustainable technologies, becoming a driver in carbon footprint reduction.

Gleason’s interdisciplinary and international teams work closely together to exceed customers’ expectations on a local and global scale. Sharing a common mission and moral values is an important foundation for collaboration and success.

• As gear manufacturers embrace Industry 4.0 technologies, from AI-based inspection to digital twins, how do you see automation and data analytics shaping the “factory of the future”?

Automation and data analytics transform the factory of the future into a highly connected, self-optimising environment. AI-driven inspection and digital twins will continuously monitor processes, predict deviations, and automatically adjust production parameters to ensure consistent quality. Real-time data sharing across machines and departments will enable faster decision-making, reduced downtime, less scrap, and more flexible, customised manufacturing. Ultimately, factories will become smarter, more efficient, and capable of delivering higher performance with fewer manual interventions.

Our design–manufacture–measure strategy drives in exactly this direction, leveraging digital twins to accurately simulate gear performance before anything is physically produced. By collecting and analysing deviations with smart metrology systems and integrating real production data into these virtual models, we can predict behaviour, identify potential issues early, and optimise key parameters. This approach shortens development cycles, enhances quality, and ensures that the final product aligns closely with customer expectations.

Gleason Intra SFTX Single Flank Roll Tester with Twin Spindle and Gleason GRSL Double Flank Roll Tester with Laser Technology, ideally suited for state-of-the-art EV gear inspection with integrated NVH analysis. 

• Gleason’s modernisation and retrofit programs help extend the life of legacy machines. How important is this for customers aiming to upgrade capabilities without full replacement investments?

Remanufacturing and machine upgrades remain an important part of our product portfolio and also part of our sustainability initiative, from mechanical rebuild to recontrols and software upgrades. In today’s world, whether it be for productivity, safety or IT security, keeping customers’ machines and equipment in general up to modern standards is a requirement.  We offer these rebuild programs through all of our global machine plants.

• Having been with Gleason for more than three decades, how has your leadership philosophy evolved in guiding a legacy company through waves of technological disruption?

I have tried to remain consistent in my core values, but done so with an awareness of our changing markets. Remaining disciplined regarding global alignment of our mission, being data-driven in decision making and valuing our employees and customers are timeless, no matter what technological trends may exist.

• With such a diverse customer base, spanning automotive, aerospace, wind, mining, and more, how does Gleason decide where to focus its R&D and product development efforts?

For the most part we try to make our products as universal as possible to serve a variety of end-markets. We will create special features which may be pointed to certain industries.  Our ability to nimbly serve different markets is part of what has aided the Gleason’s longevity.

Gleason provides a complete gear technology ecosystem to its customers, including design software with digital twin technology and feasibility checks, manufacturing machines, metrology systems, tools and workholding, as well as Smart Loop software to feed back inspection results to manufacturing machines for potential corrective actions.

• Finally, what message would you like to share with young engineers and entrepreneurs entering the gear and power transmission industry today?

The power transmission industry is a multifaceted industry that can expose you to many, very diverse fields, as gears are used across a wide spectrum of applications. Besides the interesting customers you may interact with, there is a range of career opportunities from mechanical design, software, manufacturing engineering, application engineering, technical sales, and more. Gears are still one of the more challenging fields, trying to balance precision and productivity, offering great opportunities for learning and professional growth.