McCauley Propeller Systems

McCauley Propeller Systems

Company type	Division
Industry	Aerospace
Predecessor	McCauley Aviation Corporation, McCauley Steel Propeller Company, McCauley Industrial Corporation
Founded	January 1, 1938 (1938-01-01) in Dayton, Ohio, United States
Founder	Ernest G. McCauley
Headquarters	Wichita , United States
Area served	Worldwide
Key people	James W. Simiister (former VP and GM), Keith Kerschen (interim GM, 2000), John C. Dussault (former GM), Walter Voisard (former GM)
Products	Aircraft propellers, propeller spinners, governors, wheels, brakes, related components
Owner	Textron Aviation (parent company)
Number of employees	230 (1967)
Parent	Textron Aviation

McCauley Propeller Systems is a U.S.-based manufacturer specializing in aircraft propellers, established in Dayton, Ohio, in 1938 by Ernest G. McCauley. At its height, it was considered either the largest producer of aircraft propellers globally or at least the foremost within general aviation. For the majority of its existence, McCauley maintained its headquarters near Dayton; however, in the 21st century, it relocated to the facilities of its parent company, Textron Aviation, located in Wichita, Kansas.

Initially launched as McCauley Aviation Corporation, the company was incorporated under the name McCauley Steel Propeller Company in 1939. It later underwent name changes to McCauley Industrial Corporation and subsequently became the McCauley Industrial Division of Cessna Aircraft. Cessna acquired McCauley in 1960. When Cessna itself was purchased by Textron Corporation in 1992, McCauley was integrated into Textron Aviation. The brand adopted the name "McCauley Propeller Systems" in September 1996.

History

McCauley began operations in 1928 in West Dayton, Ohio, with a workforce of roughly 18 employees and initially focused on manufacturing wooden propellers. The company was a trailblazer in developing the ground-adjustable, solid-steel propeller in 1941 and produced around 20,000 units during World War II. By 1946, McCauley introduced forged aluminum propellers and, a year later, launched the first all-metal fixed-pitch propeller designed for light aircraft under the "MET-L-PROP" label.

By 1967, McCauley had broadened its offerings to include propeller spinners and governors. It operated from a 160,000 square foot facility in Dayton with a staff of approximately 230 employees and annual revenues near $5 million. Between 1976 and 1978, Cessna explored relocating McCauley’s manufacturing plant either to a larger site at Dayton International Airport or to Wichita, Kansas—the latter being Cessna’s headquarters and former home of McCauley's CEO Dussault. Despite Kansas providing tax incentives and right-to-work advantages favorable for expansion, McCauley ultimately chose to move to Dayton International Airport, preserving its local market ties.

By 1982, the company had expanded into producing aircraft wheels, brakes, and related components. However, after facing product-liability litigation in 1986, Cessna—McCauley's parent and principal customer—ceased production of most propeller-driven aircraft except for the Cessna Caravan model. This decision led to a downturn in McCauley’s sales.

In 1992, General Dynamics sold Cessna to Textron Inc., which initially planned to divest McCauley's Accessory division in 1993 but eventually retained it within its corporate portfolio. The enactment of the General Aviation Revitalization Act in 1996 curtailed manufacturers’ product liability exposure, allowing Cessna to restart production of propeller-driven aircraft using McCauley products and thereby stimulate revenue growth.

In late 1999, production of the Cessna 172 was suspended due to defects detected in McCauley propellers. While McCauley continued operations uninterrupted, Cessna responded by replacing both its general manager and quality manager shortly thereafter as part of strategic leadership changes emphasizing improved quality control and financial results.

Key personnel

Ernest G. McCauley, founder and innovator in aircraft propeller technology, held numerous patents related to controllable propellers and was recognized for his service to the U.S. government from 1918 through 1950. By the mid-1940s, a board appointed by McCauley removed him from executive duties. He died in 1969.

In 1954, Vernon W. Deinzer advanced from shop superintendent to vice president of manufacturing and later served as general manager. After Cessna acquired McCauley in 1960, Deinzer led the Cessna-owned McCauley Industrial division until John C. Dussault—formerly technical services manager at Cessna—assumed general manager responsibilities in 1967.

During the early-1980s economic downturn, Dussault along with six other senior executives accepted early retirement offers in 1982. Walter Voisard—a mechanical engineer and licensed pilot who had been vice president and chief engineer at McCauley prior to its acquisition by Cessna—then took over as general manager.

In January 2000, following quality concerns involving McCauley propellers supplied to Cessna, vice president and general manager James W. Simiister was replaced. Keith Kerschen, who served as director of operations administration at Cessna, assumed interim leadership of McCauley pending appointment of a permanent successor.

See also

• List of aircraft propeller producers