Author Archive

Taking control of training efforts

January 25th, 2013
By: Dan Davis

A&E Custom Manufacturing, Kansas City, Kan., isn't much different from other metal fabricators today. It is looking for the right skilled employees.

"If we could find the people, we would probably add four to five employees," said John Jaixen, A&E's general manager, in December. Specifically, he would bring on talented welders for the second shift and inventory help—if he could find the right people.

Needless to say, A&E isn't alone. In October 2012 the Boston Consulting Group issued a report saying that manufacturing companies had 80,000 to 100,000 open positions for skilled workers. That's dwarfed by the 600,000 openings cited in a 2011 survey from Deloitte Consulting and The Manufacturing Institute. Sure, that's a big disparity, but the fact is that the current manufacturing workforce isn't getting any younger; the U.S. Bureau of Labor Statistics puts the average age of manufacturing workers in the U.S. at 56. (more...)

Mexico's other competitive advantage

January 11th, 2013
By: Dan Davis

It used to be just labor cost, but apparently Mexico has another secret weapon in trying to expand its role as the world's manufacturing partner: It can churn out engineering and manufacturing talent for the large multinational manufacturers looking to locate in North America.

Don't believe it? Look what's happening elsewhere in the world. (more...)

Wanted: Experienced workers who never retire

December 13th, 2012
By: Dan Davis

"They've tried for two years to find my replacement, but they didn't find one yet," said 67-year-old Gil Smith, a second-shift welding technician for Rose City Manufacturing, Springfield, Ohio.

He shared that fact with me after saying that he had read the December edition of the Fabricating Update e-newsletter where I mentioned that metal fabricators need to keep older workers around because companies simply aren't prepared to have all of that valuable knowledge walk out the door permanently to enjoy retirement. It's not that workers can't be found and trained to operate the machines and systems; it's the fact that those workers won't know what to do if faced with unforeseen circumstances that prevent them from operating the same machine and systems they were trained to operate. They simply don't have the experience. (more...)

It's a jungle out there

November 30th, 2012
By: Dan Davis

What makes a jungle a scary place? It's probably fear of what might happen—not so much of what has happened. Uncertainty feeds paranoia, and paranoia forces one to lose focus. Without focus, a person is more likely to find himself in a dangerous spot.

Upton Sinclair observed those dangers firsthand when he went undercover for several weeks in 1904 in the Chicago stockyards. The journalist observed the dangers that unskilled workers had to cope with every day, the sickness that was rampant among the workforce, and the abuse that was heaped upon the workers by greedy company management. Back then the workplace could be a deadly place for someone that didn't have his wits about him.

Sinclair's book The Jungle, published in 1906, brought these conditions to the attention of most Americans and eventually led to legislation that set federal standards for meat and food inspection. Sinclair actually wanted the book to generate more interest about worker safety and well-being—which didn't really happen until several years later. (more...)

FABTECH 2012: A reason for optimism

November 16th, 2012
By: Dan Davis

The year was 2008. FABTECH, North America's largest metal fabricating and forming technology tradeshow, was making its first visit to Las Vegas. The opening day of the event generated a lot of excitement because more visitors attended that first day than had ever attended a FABTECH opening day, which included the typically larger Chicago shows. Many attendees were uncertain about the economy cooling down, but plenty of others blamed such talk on the liberal media trying to sabotage the economy. Several weeks later, however, any enthusiasm soon faded; the U.S. economy seemingly fell off of the cliff.

The year is 2012. FABTECH returned to Las Vegas, Nov. 12-14. The opening day generated similar numbers as the show four years ago. Attendees still don't know how much their taxes will go up in 2013 or just how much the federal government's new health care mandate will cost them. Meanwhile, some attendees point the finger at the liberal media for not recognizing that the metal manufacturing sector is operating at near-full capacities. Business is good, but uncertainty remains high even after the presidential election. Can the Republican majority in the House of Representatives work with the Democratic majority in the Senate to provide a roadmap that helps the federal government avoid the huge mandatory budget cuts that are linked to the "fiscal cliff"?

It appears what is old is new again—much to everyone's frustration. But there is good news, and that is fueling quiet optimism among the metal fabricating community walking the floors of FABTECH 2012. Everyone is lean and means to grow the business. Everyone is waiting on the right moment to do it, however.

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Fabricating real value

November 9th, 2012
By: Dan Davis

As I was watching Hurricane Sandy coverage on Oct. 29, I flipped on CNBC only to find a reporter lamenting the fact that the New York Stock Exchange (NYSE) might be forced to close for a second day due to inclement weather, marking the first time since the Blizzard of 1888 that weather had forced the Wall Street institution to be closed for two consecutive days. Additionally, this closure was coming at the end of the month when traders typically price financial portfolios. Oh, the horror!

Meanwhile, I was just thrilled that my 401(k) actually might not lose money for two consecutive days.

Beyond my self-centeredness, however, I couldn't shake the thought that so much attention was being placed on the NYSE while the area police officers, firefighters, public service crews, electrical workers, and storm recovery specialists were working around the clock to get New York up and running after Sandy blew through town. Certainly, financial trading is important to a modern economy, but life doesn't stop if financial traders can't make a phone call or send an e-mail. You can't say the same about the people who restore power and clear roads; if they don't show up, no one else can show up for their jobs. (more...)

Fabricating on the fast track

November 2nd, 2012
By: Dan Davis

UPI Manufacturing, Eagle, Wis., began with a noble thought: How can a company help out U.S. soldiers? The most obvious answer was to start manufacturing to support the war effort. So in 2003 the Dretzka family, who ran Underground Pipeline Inc., jumped into the metal manufacturing business. Since then, it's been a fast ride as the business has expanded.

In the years 2006-2009, UPI was honored with Supplier Excellence Gold Awards from the Defense Supply Center and named Innovative Business Performer of the Year by the Defense Logistics Agency. UPI is now a multimillion dollar business with 65 employees. On Nov. 1, the company hosted an open house to mark the expansion of the building it's been in since 2007; UPI added 36,000 sq. ft., which includes three bays, to its 24,000-sq.-ft. headquarters.

The interesting thing about UPI's skyrocketing growth is that the company really wasn't heavily involved in metal fabricating. It was doing mostly machining work prior to 2010. (The company currently has three vertical machining centers, two horizontal machining centers, and a CNC lathe.) At that time it invested in its first 90,000-PSI Flow waterjet table, which happened to have two cutting beds, allowing one to be loaded while cutting takes place on the other bed. Welding  was soon added as the company was bringing in more armor plate work. Today the company has 10 AWS-certified welders capable of working with armor plate, stainless steel, mild steel, and aluminum. (more...)

Getting up to speed on "soft" costs

October 18th, 2012
By: Dan Davis

I've got a friend that coordinates purchasing relationships between U.S. manufacturers and Chinese part suppliers. That may rub some people the wrong way, but his current occupation is just part of a natural evolution. He once acted solely as a manufacturer's rep for manufacturing service providers in the Midwest, but had to change his approach as everyone began to seek overseas sourcing connections. In typical American success story fashion, he saw an opportunity and jumped on it.

But this story isn't about him; it's about one of his customers. This one in particular had been a very satisfied customer until the arrival of new company management. The new regime wanted a review of all existing supplier relationships. In short, management wanted to see what cost savings could be gained by intensely scrutinizing current contracts.

My friend has been through these scenarios before, and he prepared a plan. How could he improve his position while helping out the customer? He knew it wasn't just about parts and prices; it was about solving a customer's pain—even if the company didn't know it had one. (more...)

Magical fabricating tour

October 12th, 2012
By: Dan Davis

If you weren't a part of The FABRICATOR's Technology Summit in early October, you missed a great learning experience. About 50 attendees visited six fabricating operations, two manufacturers of laser equipment, and one systems integrator of custom laser machines. If the event didn't "ignite innovation"—as its tag line suggested—it certainly got some people thinking about how they might change their own operations.

What exactly did attendees see as they traveled around Minnesota's Twin Cities? They got to see everything, from the automated manufacturing processes used to fabricate Hoffman boxes—one of the most recognizable brands in the metal manufacturing industry—at Pentair Technical Products, Minneapolis, to the manufacturing might needed to construct giant grain handlers at Schlagel Inc. in Cambridge, Minn. At those stops and others they saw the latest in automated storage and retrieval systems that feed material to laser cutting machines with no human intervention; specialty laser cutting devices tailored for industries such as medical device and aerospace parts manufacturing; and even a fiber laser that ripped through tubes, cutting shapes in a matter of seconds. (more...)

Make Manufacturing Day a memorable one

September 21st, 2012
By: Dan Davis

"Want to come out to St. Francisville this Saturday and take a tour of the plant?" my dad asked me one night during dinner back in 1986.

Knowing that such a visit would cut into my sleep time over the weekend, I declined with the grace and panache of a teenager. "Not really," the response might have come out.

I still wince when I recall that short-lived conversation.

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