Describes the initiation and process of a program which addresses very large gears (approaching 200 inches in diameter) and a number of pinion configurations. Configurations range from long@ integral@ solid on-shaft designs to multiple shell pinion designs. Most are carburized and hard finished; all meet or exceed AGMA Quality Class 10. Presents the general design procedures and overall implementation of the design and manufacturing program. Describes the results in terms of improved mill gear system experience.