It is not just business

Tuesday, April 23rd, 2013
By: Tim Heston

Troy Berg, president of Dane Manufacturing, a contract fabricator in rural Dane, Wis., attends equipment auctions not just to find a deal on equipment, but to learn. With success comes confidence and determination; with failure comes soul-searching, self-scrutiny and, quite often, unfiltered truth.

Berg has gotten quite a bit of truth. This morning, he told me of an auction visit in 2007 to a large fabricator on the West Coast. It was an unusual opportunity, because only half the shop was shuttered. He and other fabricators were in an idle portion of the shop full of lightly used, high-quality laser cutting machines, press brakes, and high-end material handling. The other half of the floor was still humming. Punch presses, lasers, and the buzz of welding arcs permeated the place.

Berg didn’t buy anything, but he did see a man in a blue maintenance shirt, and he walked over and introduced himself. They started chatting. Then Berg, like a true investigative reporter, dove in and asked the question: “So what the heck happened here?”

Read the rest of this entry »


Defining a champion

Tuesday, April 16th, 2013
By: amandac

As I was putting together this issue’s Shop Stories featuring Tim Baber of College of the Canyons, Santa Clarita, Calif., one word from our conversation stuck out in my mind: Champion.

Champion is defined by Webster’s Dictionary as a warrior or a fighter; a militant advocate or defender; one that does battle for another’s rights or honor.

A champion quite simply is someone who makes their situation or surroundings better; someone whose personal investment runs so deep outsiders have a hard time separating the entity from the individual. Read the rest of this entry »


A litany of amateur mistakes

Tuesday, April 16th, 2013
By: Eric Lundin

At 7:03 pm on November 1, 1955, a DC-6B (United Airlines Flight 629) crashed near Longmont, Colorado. The Civil Aeronautics Board and the FBI carried out a comprehensive recovery effort, and eventually pieced together most of the airplane. The tail had severed off cleanly, and when engineers from United and the manufacturer, Douglas Aircraft Corp., offered no viable explanation, the FBI considered it an act of sabotage.

Exhaustive interviews with family, neighbors, and business associates of the passengers led the FBI to focus on Jack Gilbert Graham, whose mother was a passenger. Graham had a suspicious past to say the least. A restaurant owned by Graham’s mother, and managed by Graham, had once been damaged by an explosion; years earlier Graham had been convicted of forgery; and recently he had filed an insurance claim on a pickup truck that had stalled on a railroad track. He also had a motive; before the flight, Graham had taken out a life insurance policy on his mother.

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Careers for manufacturing professionals, not button pushers

Monday, April 15th, 2013
By: Tim Heston

When it comes to the economy, everyone may be fretting about unknowns, yet manufacturing still is making headlines--this week on TIME magazine’s cover. The article tells a familiar story: Manufacturing is back, but don’t expect the industry to hire people en masse. Automation has reduced the number of people necessary to make a widget, and the people who remain must be technically savvy and think on their feet. In the middle of the article, the magazine spread shows a battery plant, void of human life save for one person with an iPad, overseeing the automation.

I wish the authors had spoken with our columnist Dick Kallage of KDC & Associates; or Rajan Suri of the Center for Quick Response Manufacturing; Gary Conner, of Lean Enterprise Training (who has an article coming up in the May issue of The FABRICATOR). If they had spoken with any one of them, they would have discovered that the GE plant isn’t indicative of most U.S. manufacturers--that is, small companies.

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Manufacturing forecast: Sunny days ahead

Friday, April 12th, 2013
By: Dan Davis

Is current economic news making you unenthusiastic about the rest of this year and 2014? The editors at The Kiplinger Letter say not to fret. Manufacturing's future in the U.S. appears to be pretty good in the near term.

In the early April newsletter, editors suggested that, even though manufacturing may appear to be losing some of its momentum this year, it will continue to be a strong driver of growth during this "feeble" economic expansion.  Manufacturing growth is expected to be 2.2 percent in 2013, just a little higher than the forecast GDP growth of 2 percent, but could be greater if public pressure forces lawmakers to moderate the effects of budget cuts related to the federal sequester. In 2014 manufacturing growth could hit 3.5 percent. In fact, manufacturing production levels should reach 2007 levels in 2014.

To dig deeper into the forecast, The FABRICATOR talked with Karen Mracek, a Kiplinger Letter associate editor. Read the rest of this entry »


Backbone of America deserves a round of beer

Wednesday, April 10th, 2013
By: Vicki Bell

As content manager for thefabricator.com, one of my job duties is to moderate comments left for articles on the site. This is an interesting task. Some comments are blatant promotions, complete with links, for companies that want to use this opportunity to hawk their products. While you have to give them credit for exploring all marketing possibilities, they are wasting their time in this particular endeavor. Their comments are deleted.

Some comments contain questions, and others offer good feedback about the topic. Every now and then, I run across one that makes me smile and just plain feel good. Such was the case when I read Christopher W.’s comment to the article “Welders on welding.” Read the rest of this entry »


Dysfunction junction

Friday, April 5th, 2013
By: Dan Davis

How could the U.S. Congress screw up funding job training programs? Manufacturers need specialized workers, and the unemployed need training for those unfilled positions in manufacturing. Sounds simple, right?

Nothing is simple nowadays.

In mid-March Republicans in the House of Representatives passed the Supporting Knowledge and Investing in Lifelong Skills (SKILLS) Act, which reauthorizes the Workforce Investment Act (WIA). The bill aims to eliminate and consolidate 35 duplicative and ineffective employment and training programs administered through the WIA. Read the rest of this entry »


Hands off the merchandise!

Thursday, April 4th, 2013
By: Eric Lundin

In early March, my colleague Vicki Bell wrote a blog about a common and highly dreaded problem these days: Metal theft. I am sure the main target is copper, which typically fetches more than $3.00 per pound (spot price), and it probably started with stealing plumbing pipe from abandoned buildings. Thieves have gotten bolder and, while the evidence is largely anecdotal, fully functional HVAC systems and other copper-rich items have become targets.

And the thieves have gotten bolder still. Vicki cited a specific instance at Metcam, metal fabricator based in Alpharetta, Ga. In this case, the suspect was loading sheets of metal into his truck and, when questioned by a deputy whether he had permission, he said, “I didn’t know I couldn’t do this.” Hiding behind a building, on private property, under cover of darkness, taking things that didn’t belong to him. And he didn’t know it was wrong. Bold. Read the rest of this entry »


A race to the bottom

Thursday, April 4th, 2013
By: Vicki Bell

“Wal Mart is the death knell for small business everywhere they open shop. Wal-Mart is good for small business in the same way amputation is a successful weight-loss program. Wal-Mart is killing America, and if you shopped there this week, here’s hoping the American job you just shipped overseas is yours!”

So reads a comment about the money.cnn.com article “The Wal-Mart economy’s big winners,” which focused on four small U.S. businesses that “hit the big one” by securing Wal-Mart orders. There are some lessons to be learned from each of these businesses, lessons that are as basic as any in business: Listen to the market; find a need and fill it; and be persistent. There also are lessons to be learned from the comments left for this article. But it doesn’t appear that these lessons are getting through. Read the rest of this entry »


College basketball and cross-training

Friday, March 22nd, 2013
By: Dan Davis

'Tis the time of year when people might be secretly paying more attention to NCAA basketball tournament games than work and, in some cases, actually leaving work early to watch the afternoon first-round games. Even though March Madness might sap worker productivity, it still might hold meaning for fabricating management.

How could that be? Well, recent research suggests that sports teams with players who can play more than one position can field a better lineup on a more regular basis than teams without those types of players. Those teams also show more resiliency when it comes to player injuries.

More specifically, "The value of flexibility in baseball roster construction," a report prepared by Timothy Chan of the University of Toronto and Douglas Fearing of the Harvard Business School, examined statistics from the 2012 Major League Baseball season and found that players with the ability to play multiple positions were responsible for up to 15 percent of the teams' runs. The researchers then compared this flexibility to that of automotive supply chains that can adapt quickly to changes in supply and demand, helping production remain as efficient as possible. Both baseball teams and automotive manufacturers want to stay at their top performance level even in the face of obstacles—which might be a major injury for a baseball team or a material shortage for a supply chain.

If metal fabricators haven't realized the importance of that type of flexibility on their own shop floors, they likely haven't seen profits rise with the uptick in the metal manufacturing sector. They probably have a problem getting products through the shop, which prevents them from getting paid as soon as possible. Read the rest of this entry »