Author Archive

Pi and K factors: The mathematical beauty of sheet metal

July 10th, 2012
By: Tim Heston

I was never a math wiz, but I was blessed with good teachers. In high school, I remember sitting in Algebra II class and hearing one of my fellow students give a loud sigh before he raised his hand: “When will we ever use this?” My teacher shot back. “See the pencil you’re holding? The people who made it couldn’t have done it without the problems you’re working on right now.”

Sure, my classmates gave him the expected groans, but when I think back to that statement, I know we need more teachers like him. Even in this economy, manufacturers crave people who don’t get scared by adding and subtracting three or four places to the right of the decimal point. Operating a press brake, you basically work with a bunch of triangles (V die opening and bend angles) and degrees of a circle (bend radii). Algebra and (especially) geometry and trigonometry are everywhere.

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Of fire and metal fabrication

July 3rd, 2012
By: Tim Heston

Manufacturing didn’t fare so well last month, falling just slightly into contraction territory, as measured by the Institute for Supply Management. The data support what a few shop owners have been telling me.

“Business is softening.”

That was Bruce Hupfer, director of technical sales at Qualtek Manufacturing. The 40 people at this manufacturer know how tumultuous U.S. manufacturing can be. At one point, much of its business came from stamping computer chassis. After that business left for Asia, the company made a push for diversification. Today the stamper serves the medical field, renewable energy, as well as general industrial customers.

The shop has technology that can form components like few competitors can. The company invested in several servo-presses with a ram stroke that’s fully controllable. The ram can change speed during forming, dwell at the bottom, and even rock back and forth to ensure the metal of the formed part has “settled” into its final shape. This technology can take on some seriously complex parts.

The company also offers finishing and heat treatment services, making it one-stop shop for many customers. The shop’s diverse capabilities and customer base will most likely protect the firm for what may be a bumpy road ahead.
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Metal fabrication, patent pending

June 26th, 2012
By: Tim Heston

Welders and other workers at The Roberts Co. in Winterville, N.C.--part of this year’s FAB 40 list of successful contract fabricators--are used to signing secrecy agreements from customers. Dave Staskelunas, the company’s vice president of fabrication services, said that more and more customers are requiring workers to keep quiet as they weld and form proprietary materials or designs. These designs aren’t patented, either. The risk of someone else coming out with the idea is probably less than someone outright stealing it during the drawn-out patent application process.

As a recent Bloomberg article aptly put it, the U.S. patent system “gives inventors a limited monopoly on their ideas in exchange for revealing them to the world so that others can build on them.”

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The pruned metal fabrication supply base

June 12th, 2012
By: Tim Heston

Natural disasters turn people’s thoughts toward risk. Last year, between floods and tornados and other Weather Channel fodder, I visited several fabricators told me about their customers’ concerns about mitigating supply chain risk. For years, large OEMs have pruned their supply chains to the nth degree, giving more business to fabricators who perform well, order after order. Fabricators who don’t perform are pruned.

Then came last year’s floods and tornadoes. This year, some are worried about an economic slowdown, and some sectors have more to worry about than others. As the American Wind Energy Association reports, unless Congress renews a production tax credit for 2013, makers of wind tower components may need to shed 10,000 jobs due to an anticipated slowdown in orders. Vic Abate of General Electric’s renewable energy business told Bloomberg he expects to dramatically reduce the number of parts suppliers. As Bloomberg reported, “The company might have as many as 10 suppliers for certain components now a figure that may dwindle to just three once he is finished pruning.”

Ouch.

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A metal fabricator and a Vega

June 7th, 2012
By: Tim Heston

1971 Chevrolet VegaThirty-nine years ago yesterday Ed Kittelson--with grinder in hand--spent his first day working at a fab shop in Anoka, Minn., northwest of Twin Cities. It was a homecoming of sorts. His parents had moved south to escape the cold, but Kittelson never felt quite at home. So the day after high school graduation, he packed his 1971 Chevy Vega hatchback and, long hair and all, headed back north to Anoka.

For years he spent time on the floor working the fabrication equipment of the day, punching sheet metal using a traditional duplicator stylus. He climbed the ladder to night shift supervisor, and then moved on to other manufacturers, working in sales and shop management; some jobs were great, others weren’t. In the early 1990s he found a two-person fab shop for sale, and he needed a $50,000 down payment on the loan to buy it. Where did he get the money?

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Fabricating the American Dream

May 29th, 2012
By: Tim Heston

Many are rethinking the American Dream these days, especially over Memorial Day. The dream, however idealistic, is worth fighting for. But what is that dream, exactly? National Public Radio’s Ari Shapiro put it this way: “Though the phrase has different meanings to different people, it suggests an underlying belief that hard work pays off, and that the next generation will have a better life than the previous generation.”

He added that the notion is uniquely American. Although we don’t feel people are entitled to success, we feel that hard work and playing by the rules should lead us to something better than our parents had. Success, we feel, is within our control.

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The model of a modern major fabricator

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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The great asset of a graying manufacturing work force

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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Private equity and the fabricator

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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Producing more versus hiring more

April 17th, 2012
By: Tim Heston

A few weeks ago Rob Olney, president of ETM Manufacturing, a contract metal fabricator in Littleton, Mass., told me something that exemplifies what makes people proud of American enterprise. But it also worries people who need a lower unemployment rate to get re-elected.

“[Since 2006] we’ve tripled our annual sales and less than doubled our personnel.”

Olney and other managers of successful fabricators--the “winners” emerging from the Great Recession--had good foresight in 2009 and 2010. They reduced waste, especially work in process, and invested in equipment that sped work flow and reduced lead time. They’re producing more with fewer people. The result: Sales are soaring; hiring, not so much, and (most significant) neither is overtime.

Mark Chadwick, a manager at St. Louis-based CR Metal Products, called this phenomenon “painless growth.”

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