Safety first, everything else second

Wednesday, May 16th, 2012
By: Dan Davis

Manufacturing is a matter of life and death.

Ask company owners what that statement means, and they might reply that every strong country needs a robust manufacturing sector. Ask manufacturing workers the same question, and they will tell you it's about their ability to go home safely to their families. They know the everyday risks because they live with them each and every workday.

The hazards? Watch out for the heavy weldment being hoisted over your head. Listen up for the lift truck whizzing by with the pallet of parts that haven't been secured tightly. Check to see if that press brake is shut down before performing routine maintenance. In summary, keep your head on a swivel and be aware at all times, because a metals manufacturing environment can be a dangerous place. Read the rest of this entry »


The model of a modern major fabricator

Tuesday, May 15th, 2012
By: Tim Heston

Steve Wiseman is honest. “We’ve forecast about a 15 percent growth this year, but mind you that 2011 was terrible for us.”

The vice president of operations at Nu-Way Industries--part of our Fab 40 list of top U.S. fabricators, to be featured next month--knew that when the AT&T and T-Mobile merger fell apart, the fabricator’s telecom business would suffer. “[Telecom companies] are suffering from a lack of capital to expand their networks,” he said, adding that the Des Plaines, Ill., fabricator has always focused on diversification, “and we’ve been fairly diversified over the years. But you can get caught in some unexpected, opportunistic business.”

Over the past year the company has gained work from new and existing customers, but it analyzes new opportunities carefully. If a prospect offers lucrative work over the next few months, the fabricator can take the job, of course, but it looks at such opportunity with eyes wide open. “You have to look where you have capacity, and you need to make sure you are not going to sacrifice existing relationships for some opportunistic piece of business that’s here today or gone tomorrow. So we look very hard at who a customer is and the potential for growth.”

Such savvy management is a necessity now, postrecession. Many small shops that offered limited services and relied on a handful of customers have shut their doors, Wiseman said. Companies with diverse customer bases, broad services--including engineering and design--have remained, and “now they’re all hungry and looking to grow their business again. It’s become a much more competitive marketplace for everybody.”

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Take a ride in a battery-powered what?

Thursday, May 10th, 2012
By: Eric Lundin

It wasn’t that long ago that Alessandro Volta built the first battery. In 1800 he made a stack of metal plates, alternating zinc and copper, with each pair separated by layers of cloth soaked in brine. Today’s batteries are more sophisticated but use the same principle to create electromotive force, or EMF. The basic unit of EMF is the volt, named in Volta’s honor. Read the rest of this entry »


The great asset of a graying manufacturing work force

Tuesday, May 8th, 2012
By: Tim Heston

Earlier this week I spoke with Frederick Hartman at Needham, Mass.-based Vita Needle, a company unique in several respects. The metal fabricator allowed Caitrin Lynch, associate professor of anthropology at the Olin College of Engineering, also in Needham, to spend five years at the stainless steel tubing and needle manufacturer.

Oh, and one more thing: The median age of the Vita Needle employee is 73.

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How healthy is your business?

Thursday, May 3rd, 2012
By: Vicki Bell

The first quarter of 2012 is behind us. Companies of all sizes are examining their first quarter results to gauge how well they are doing and plan for the months ahead. Investors wait anxiously for corporations to tally, massage, report, and spin their figures, comparing them to economists' predictions and the previous year's performance—better or worse.

As reported on cnn.com, "General Motors reported strong first-quarter earnings on good results in its domestic market Thursday, but its bottom line took a hit from rising losses and special charges in Europe. Read the rest of this entry »


Private equity and the fabricator

Tuesday, May 1st, 2012
By: Tim Heston

The Roberts Co., a major industrial fabricator in the Southeast and one of this year's FAB 40 companies (to be published in our June issue), probably wouldn't be the company it is today without Private Equity. Since Main Street Resources purchased the company in 2008, just months before the financial crash, Roberts Co. has benefited from some major personnel investment, including a swath of new senior managers. They're not outsiders, but experienced fabricators. They know the chess game involved when executing a major industrial project. All the right pieces—engineering, fabrication, field erection,and maintenance services—must be moved to the right place at the right time.

According to company sources, the private equity firm gets high-mix, low-volume manufacturing. In Roberts' case, the company is benefiting from major company investments, including a new, 90,000-square-foot fabrication facility that opened late last year. The company prepared for the upswing during the downturn, and Roberts' current growth projections are evidence that the gutsy strategy worked.

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How long has this been going on?

Thursday, April 26th, 2012
By: Vicki Bell

How long have we been talking about a welder shortage? If you type "welder shortage" with the quotation marks in thefabricator.com's search box, you will retrieve a list of 367 articles; without the quotation marks, the list grows to 619. 

The very first article in both searches, "Feeling the effects of a welder shortage: The search is on to find skilled workers," was written 11 years ago. The author described the need to replace aging, skilled welders as "acute," and quoted then president of the Hobart Institute of Welding Technology, Dave Manning: "The need for skilled workers will become more of a problem in the next three to five years, as 50 percent of the welders in North America retire."

I can't say if Manning's prediction that 50 percent of the welders in North America have retired has come true, but I rather doubt it. Feedback we've received over the years to e-newsletter questions asking readers about their retirement plans indicates that many welders have put retirement on hold for various reasons. Even so, the welder shortage is acute. Read the rest of this entry »


The risks and rewards of genetic engineering

Wednesday, April 25th, 2012
By: Eric Lundin

It could be a dream come true or the latest scene in a long nightmare. Dow AgroSciences has developed a genetically engineered corn, named Enlist, to withstand herbicides containing 2,4-dichlorophenoxyacetic acid (2,4-D). The chemical was developed with the intention of helping to increase crop yields by eliminating nutrient-robbing weeds from farmers’ fields, and these days it is thought to be the most commonly used herbicide in the world.

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Manufacturing on the rise; pay not so much

Friday, April 20th, 2012
By: Dan Davis

Leave it to the guys at Yale University to screw up a simple headline.

I came across this article--"U.S. Battle to Revive Manufacturing—Part I" in YaleGlobal Online Magazine—but really didn't get sucked into it until I read the subhead "Job growth urged by U.S. presidential candidates may not support high standard of living." Now that's burying the main point.

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Producing more, hiring less

Thursday, April 19th, 2012
By: Eric Lundin

We’re still slogging through the jobless recovery, and while slowly falling unemployment took many by surprise in 2010 and 2011, I guess most of us have resigned ourselves to looking for reasons. There isn’t much else we can do.

Before we look for reasons, let’s look at the trend.

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