From Customer Challenge to Engineered Solution: The Story Behind Star Hydraulics’ Tow Bar Jack
For manufacturers and equipment builders, the right hydraulic solution does not always begin with a part number.
Sometimes the challenge is not one component, but the complexity created by how multiple components, suppliers, and installation requirements come together. In those situations, improving the system means first understanding the application and then determining the right path forward.
That was the situation facing one ground support equipment manufacturer that turned to Star Hydraulics.
A System Built From Multiple Suppliers
The manufacturer had long relied on a lifting system assembled from separate hydraulic pumps, cylinders, and hoses. Those components came from different vendors, adding complexity to sourcing, procurement, and installation.
The arrangement also increased the potential for installation issues and hydraulic leaks.
Rather than simply replacing one component with another, Star worked with the customer to understand the complete application and identify where the system could be simplified.
That approach ultimately led to the development of an integrated Tow Bar Jack.
Bringing the System Together
Star’s U.S.-based engineering and manufacturing team drew on its experience with similar designs to develop a tailored solution for the manufacturer.
The resulting Tow Bar Jack combined the hydraulic pump, cylinder, and reservoir into one integrated unit, eliminating the need to source and assemble those major components separately. The design was also adapted to the customer’s requirements with features including customized drain ports.
The goal was not simply to create a new product. It was to reduce unnecessary complexity around the customer’s existing process.
By integrating the primary hydraulic components into a compact assembly, Star was able to reduce the number of separate parts, hoses, and connections involved in the installation.
Nearly 50% Less Installation Time
The impact was measurable.
The Tow Bar Jack’s compact design and integrated construction reduced installation time by nearly 50%. The manufacturer also significantly reduced the amount of hardware and hose required for the lifting system.
Those improvements helped address several issues at once: installation efficiency, sourcing complexity, labor requirements, and some of the reliability concerns associated with a more fragmented hydraulic system.
For equipment manufacturers, that distinction can be significant. Simplifying a system can affect much more than the time spent installing it. It can also reduce the number of components that must be purchased, managed, connected, and supported throughout production.
A Solution Shaped Around the Customer
Customization also played an important role in the project.
The customer described Star’s involvement as more than simply supplying a finished product. Throughout the process, the team listened to the manufacturer’s needs, adapted elements of the design, and provided support as the solution moved into use.
That included customizing features such as mounting points and providing onsite support when an issue arose.
That ongoing relationship has also helped inform continued product improvements. Through field feedback and collaboration, Star has made additional design refinements to better meet customer needs.
For Star, that feedback loop is an important part of the engineering process. A solution may begin with a defined set of application requirements, but real-world use can provide additional insight into how a product can be improved.
Standard, Modified or Engineered for the Application
The Tow Bar Jack is one example of a broader approach at Star Hydraulics.
Not every application requires a new design. In some cases, a standard hydraulic product may already provide the right solution. In others, an existing configuration can be modified around specific equipment or operating requirements.
And when neither approach is the right fit, Star can work with the customer to develop a solution around the application.
That flexibility allows the conversation to begin with the problem the customer is trying to solve rather than forcing the application around an existing product.
In the case of the Tow Bar Jack, the original challenge involved separate components, multiple vendors, long installation times, and additional opportunities for installation-related problems. The final solution brought the major hydraulic elements into one integrated assembly while incorporating features specific to the manufacturer’s equipment.
The result was a simpler system, a faster installation process, and a solution better aligned with the customer’s production needs.
Engineering Beyond the Part Number
For specialized equipment manufacturers, the most useful supplier relationships often go beyond finding the right component in a catalog.
They begin with understanding the application.
The Tow Bar Jack project demonstrates how Star Hydraulics approaches that process: identify the challenge, work with the customer to determine what the application requires, engineer and manufacture the appropriate solution, and continue supporting it once it reaches the field.
Whether the answer is a standard product, a modified configuration, or a newly engineered solution, the objective remains the same: provide a dependable hydraulic solution built around what the customer actually needs.
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