Rave on, Clear Lake

Friday, February 3rd, 2012
By: Dan Davis

The fun thing about metal fabrication is how a fabricator's vocation can also be part of his or her fascination. Some use their welding skills to create art. Others use their metal bending and finishing skills to restore old automobiles. In one instance, a metal fabricator has even applied his metalworking skills to guitar-making.

Brad Ufford's work has sparked the fascination of a whole town, if not a whole generation of people. The fabricator, who works in the R&D department of Sukup Manufacturing Co. (http://www.sukup.com) in Clear Lake, Iowa, did most of the work on the new artwork anchoring Three Stars Plaza. By the way, those stars would be Buddy Holly, Ritchie Valens, and J.P. "The Big Bopper" Richardson—the three music legends who died in a plane crash after wrapping up a concert at the town's Surf Ballroom on a chilly night on Feb. 3, 1959.

The artwork is designed to mimic a central spindle with three stacked records. However, these records are not made of vinyl but of seven-gauge stainless steel, with a combined weight of 3,900 lbs., and a 15-ft., 24-in.-diameter steel spindle that weighs 1,600 lbs.

Ufford said one of the most interesting parts of the project was all of the gas tungsten arc welding that was required. Even with the stainless steel discs suspended in the air, the designers and project managers wanted the records to be cosmetically perfect, which meant no blemishes. So he had to work and etch out all of the blue marks left on the stainless steel finish after the welding.

Ufford doesn't think about the work as being that special. Sure, it's the focal point for a town so closely linked with the legendary musicians, but from a fabricating standpoint, it's just another project. In fact, Ufford said he gets more of a kick working on his automobile restorations.

"Buddy Holly is a little bit before my time," he said with a laugh.

It's before my time as well, but the music still remains pretty important to me. It's an extension of my childhood—always listening to my dad as he played his 1950s tunes even into adulthood. He never really progressed musically with the times, but that was OK. He didn't miss much in the 1970s.

Today that rockabilly sound lives on in bands like Jason and the Scorchers and the Reverend Horton Heat. They aren't household names, but they and other bands are keeping that original sound alive—albeit at a slightly faster pace. A tribute album to Buddy Holly was released in 2011, again proving Don McLean may have been a little premature in singing that Feb. 3 was the day the music died.

(If you don't like artist interpretations of original music, you might want to steer clear of this CD. In fact, Paul McCartney's performance of "It's So Easy" might scare you away from tribute albums forever. Sorry, Sir Paul.)

Once again, a metal fabricator's work makes a big impact on a community. Ufford and Sukup Manufacturing can feel confident that their contributions won't fade away.


Manufacturing and the State of the Union

Wednesday, February 1st, 2012
By: Tim Heston

For the past two years Mary Isbister, president of Wisconsin fabricator GenMet (one of The FABRICATOR’s past Industry Award winners), had a friendly bet with colleagues of the Manufacturing Council, a group that meets to propose ideas to Commerce Department Sec. John Bryson, who in turn reports those ideas to the president.

How many times would the president mention manufacturing in his State of the Union address?
Read the rest of this entry »


Advice for Ken about his welding career

Wednesday, January 25th, 2012
By: Vicki Bell

Are you among those who "like" The FABRICATOR page on Facebook? If so, you may have seen the January 11 post from Kenny Johnson, who wrote: "Where does everyone see the future of fabrication in the U.S.? Certified welders, or welders with degrees but no certifications? I ask this because I am looking at taking some classes and getting certified."

Perhaps no one is more qualified to answer Ken's questions than  readers of the "Welding Wire," e-newsletter. We put the questions in the January issue, and here's what some of the readers had to say. Read the rest of this entry »


Busy times, busy shops

Tuesday, 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.
Read the rest of this entry »


Manufacturing deserves special treatment

Friday, January 20th, 2012
By: Dan Davis

I apologize for being absent from the blog for most of the past six weeks. I guess I got wrapped up in Republican primary politics coverage.

That's a joke. I also was engrossed in "Storage Wars" and "American Hoggers" on A&E.

But it's kind of hard to ignore the political proceedings that are taking place all over the U.S. An election year means some sort of change is coming, and metal fabricators are no different from any other voters: They hope the change is consistent with their own political beliefs. To say that there is a little interest in this upcoming election would be a grand understatement. Read the rest of this entry »


Metal stampers' take on unions: Part II

Wednesday, January 18th, 2012
By: Vicki Bell

Last week's post, Metal stampers' take on unions: Part I, revealed findings from a "Stamping News Brief" (SNB) survey about unions. It also featured comments from survey respondents—both those who believe unions are still necessary and those who don’t. Those who believe unions are to blame for lost jobs in the U.S., and those who think they are not—that corporate greediness and the government are the true culprits. As promised, here are some more comments from SNB readers about unions. Read the rest of this entry »


Metal stampers' take on unions: Part I

Wednesday, January 11th, 2012
By: Vicki Bell

Labor unions continue to make news. Today, sfgate.com published the article Twinkie-Maker Hostess Files for Bankruptcy Citing Pensions, which said that the baker's latest bankruptcy filing is being blamed on the weak economy and costs tied to pension- and medical-benefit obligations resulting from union agreements.

Also in the news, Oklahoma union workers are testifying against Indiana's "right to work" initiative.

Labor unions have been cited by some as major contributors toward U.S. automakers' woes and the outsourcing of jobs. Perhaps no industrial sector has suffered more from the automakers' travails than  U.S. metal stampers. Last month, "Stamping News Brief" asked its subscribers—stamping industry professionals—to take a survey about unions. Some of the results may surprise you. Read the rest of this entry »


'My story: How I became a welder'

Wednesday, January 4th, 2012
By: Vicki Bell

If you're like me, you're interested in people's stories. We all have them, and typically they are more interesting than we might think. 

FMA Communications' editorial department—the department in which I work—got together last month to brainstorm all things related to our print and electronic publications. At the beginning of the meeting, each of us in attendance told the story of how we came to be editors with our publications. The stories of how we arrived at this same place bore both similarities and differences—not unlike the readers who responded to last month's "Welding Wire" with accounts of how they became welders. Read the rest of this entry »


Manufacturing grows … again

Tuesday, January 3rd, 2012
By: Tim Heston

Maybe those long lines of attendees at the FABTECH trade show last year weren’t red herrings. The Institute for Supply Management reported significant growth in manufacturing last month, news significant enough to send stocks skyward.

News coverage has been cautious, especially considering what happened 12 months ago. Stocks rose in January and throughout the first few months of 2011, only to plummet as the economy experienced one black swan event after another. Japan’s earthquakes and flooding in Southeast Asia and here in the states disrupted supply chains. The Arab Spring and European debt crisis has continued to add to our uncertainty, as well as, of course, that stubbornly high unemployment rate. So yes, if I were reacting to today’s market rise, I’d be glass-half-empty, too.

But U.S. manufacturing still seems to have a lot going for it these days. China’s government announced on Dec. 1 that its manufacturing was contracting just as labor disputes were expanding. The Asian factory worker is unhappy, and justifiably so. Ian Spaulding, managing director of the consultancy Infact Global Partners, had some insightful remarks for Bloomberg about China’s sputtering manufacturing engine. “In an environment where you have 10 to 20 percent turnover a month, managers start thinking of workers as machines. That creates resentments on both sides.”

Read the rest of this entry »


Metal fabricating: It's nice to be needed

Friday, December 16th, 2011
By: Dan Davis

After almost a week away from my family during FABTECH, Nov. 14-17, I returned to my family tired but upbeat, because the overall mood at the tradeshow was optimistic. Busy is good for most of the attendees and exhibitors.

In describing some of the stories I had been hearing about busy job shops and the need for new capital equipment investments, I encountered a question that stumped me a bit: "Why is metal fabricating doing well when the rest of the economy is not?" my wife asked.

It's a great question because it brings up two interesting points. First, most people don't realize that manufacturing is leading the way in this less-than-robust economic rebound following the Great Recession. Some are learning that a job in manufacturing may not be such a bad career path, especially as manufacturers continue to ask for more skilled workers to fill open positions. Second, manufacturing generally isn't in this position. The old adage goes that manufacturing is typically the first industry hit by a recession and the last one to emerge from it. Well, that's not how it's working this time. Read the rest of this entry »