Posts Tagged ‘press brakes’

Metal fabricating with focus amid chaos

January 8th, 2013
By: Tim Heston

Early last year, I recall eating lunch in the break room at Atlanta-based Metcam, which hosted a press brake training seminar run by Steve Benson and organized by the Fabricators & Manufacturers Association. Sitting across from me was a press brake supervisor, we chatted a bit about his tours of duty in both Afghanistan and Iraq. He told me some intense stories.

He had gotten a job at a local metal fabricator and had climbed the ladder quickly. His military training, it seems, helped.  He could focus. He paid attention to detail. He showed up to work like clockwork, and he was totally engaged in company’s improvement processes. To me, he sounded like a model employee. This is why I wasn’t surprised when I read an article in Forbes describing this as a trend that may abate, at least to some extent, our country’s skilled labor crisis.

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Fab reporter notebook: In lean manufacturing we trust

October 16th, 2012
By: Tim Heston

Yesterday I spoke with a production manager (on background) with a not-so-uncommon challenge. He had been brushing up on the basics of continuous improvement, including lean manufacturing methodologies adapted for the high-mix, low-volume environment.

All the talk of efficient part flow, shorter lead-times, and less inventory seemed great in theory. And the shop has made some initial steps. He had worked to reduce batch sizes to combat the large pile of work-in-process building up around the press brakes, a common bottleneck. The fabricator also revamped its material ordering to ensure raw stock for a job arrives a day or so before when needed, not a week or more.

But the fabricator had yet to launch a formal improvement effort. The shop is busy, to be sure, and managers expect the shop to be even busier next year. But this isn’t a reason not to launch a lean initiative. Indeed, improvement initiatives may make life easier. The shop performs numerous one-off jobs--a subassembly of, say, 10 or so components. All too often, jobs arrive at the assembly department incomplete, with one piece missing. Further improvement efforts may clear WIP, ease flow, and make it much less likely to lose a critical piece during an upstream process, like at laser cutting or punching.

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Busy times, busy shops

January 24th, 2012
By: Tim Heston

I started this year with a spurt of shop visits-- a sorry excuse for my lack of blogging, but there it is. One high-mix, low-volume job shop is beginning the process of reorganizing its machines into cells: a sheet metal cutting machine next to a brake, next to hardware insertion. In a bold move, the company has eliminated its cutting, bending, and hardware insertion departments. Managers made sure that workers are cross trained, so they can follow piece parts through all three processes before sending a batch--a small one, as close to single-piece-part-flow as practical--to operations downstream.

Here’s the kicker: The shop did it all with no holiday shutdown.
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Metal fabricating with a sense of ownership

August 30th, 2011
By: Tim Heston

I really like my job--but not in a corny sense. I don’t wake up and immediately whistle away in gleeful anticipation of the workday. Some days I feel I can’t write another word, while other days I type several pages before I realize that what I just wrote is either unintelligible or just plain awful.

What keeps me typing away is a sense of ownership. It’s my job to call contacts, develop story ideas, research technical information, interview experts, and write the story. I don’t work alone, of course. Throughout the process I work with editors, copy editors, and graphic artists--and one thing we share is a sense of ownership. The FABRICATOR and its sister publications represent our brand, our identity.

It’s not practical for all of us to shepherd products from beginning to end, of course. We would be at a loss trying to run a printing press, for instance. But we do monitor product quality through multiple stages of production, and it’s that sense of ownership that makes me happy about  going to work.

Last week I got my first taste of a new kind of manufacturing cell, and immediately I saw how ownership played a role. Milwaukee-based Phoenix Products makes lighting fixtures for a variety of commercial customers. It’s a high-mix, low-volume environment. SKUs number in the thousands.

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Equipment investment and hanging fruit

October 5th, 2010
By: Tim Heston

Several weeks ago I visited Ometek Inc., a contract manufacturer near the Columbus, Ohio, airport. After reading the manufacturing news this week, I started thinking about the company’s bending department. Here’s why.

This week the business world learned what it pretty much already knew. The Institute for Supply Management reported that manufacturing continues to grow, but that growth is slowing a bit. Still, the fabricated metal products sector reported significant growth; only the apparel industry grew by more.

Two quotes from survey respondents give a decent snapshot of where things stand:

"Our business is softening due to seasonal considerations. Overall, our situation is much better than 2009."

"Customers seem to be pulling back on orders. I suspect that they are trying to reduce their inventory for the approaching year-end."

The first quote is from the machinery sector, the second from transportation equipment. The verdict: Things are better than they were--not great, but better.

Then on Monday the Commerce Department reported significant gains in capital spending. In August, capital goods spending (excluding military goods and planes) rose 5.1 percent, more than many expected. Admittedly, the news was tempered by a slowdown in new orders (down one-half percent) and shipments (down 0.6 percent).  But gains in capital spending do show companies are making investments for the future.

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