{"id":3850,"date":"2022-04-08T20:38:46","date_gmt":"2022-04-09T03:38:46","guid":{"rendered":"https:\/\/www.metafab.com\/?p=3850"},"modified":"2022-04-29T09:57:10","modified_gmt":"2022-04-29T16:57:10","slug":"cost-management-through-processes-labor-in-sheet-metal-fabrication","status":"publish","type":"post","link":"https:\/\/www.metafab.com\/cost-management-through-processes-labor-in-sheet-metal-fabrication\/","title":{"rendered":"Cost Management Through Processes & Labor in Sheet Metal Fabrication"},"content":{"rendered":"

By: Aimee Sukol, JD\/MA\/MS Ed.<\/p>\n

Introduction<\/h2>\n

Unlike other industries that rely primarily on licensing or services alone, sheet metal fabrication manufacturing operations involve a host of ongoing costs. The highest expenses include labor, materials, machinery, and overhead. Overhead is frequently a significant cost that goes unaddressed, especially mistakes and flawed processes. In this article, I explore cost management\/reduction within the relationship between labor and processes\u00a0<\/strong>and offer considerations for mitigating unnecessary expenses.\u00a0<\/span><\/p>\n

Cost Reduction\/Savings in Sheet Metal Fabrication<\/h2>\n

To reduce production costs sheet metal fabrication manufacturers require all levels of experience, but of utmost and fundamental importance is basic understanding of three concepts: dimensions, math and processes<\/strong>.\u00a0 These three concepts prevent mistakes and establish both structure and flexibility in designs efficiently and cost effectively to achieve the customer’s vision.\u00a0 A core component to successful processes is communication<\/strong>.\u00a0 Sheet metal fabrication requires a host of micro-processes that include design, forming, bending, welding and powder coating that involve multiple stages and teams. Thus, cost reduction relies on the process of communication to ensure each stage of the product’s design is consistent with the original plan. Meta Fab’s own production manager, Patrick Gooden provided several examples:<\/span><\/p>\n

Cost Reduction in Communication\/Processes:<\/strong><\/p>\n

\"\"One of the biggest considerations is communication<\/span><\/i>.\u00a0 Finding a shop and communicating up front about design and their actual manufacturing capabilities is key.\u00a0 Most of the time our shop has a great amount of experience in building parts similar to what a customer is trying to achieve.\u00a0 This also means we have seen a multitude of ways to achieve essentially the same end result.\u00a0 That has given us the insight into which process is easiest to achieve the desired result and what is less so.\u00a0 Usually saving time and money just in up front cost of design work.<\/span><\/i><\/p>\n

Patrick’s reference to communication and experience can\u2019t be overstated. At this stage, communication to and between sales and engineering is vital to ensure the customer\u2019s order is understood and expectations for achieving a timely order are met. Communication combined with analytic acumen allows Meta Fab to select the best process for each project. Labor in this context requires both technical and communication skills.<\/span><\/p>\n

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Cost Reduction in Math Acumen\/Comprehension:<\/strong><\/p>\n

Forming or Bending metal.\u00a0 One consideration that is typically missed is flange length and material thickness.\u00a0 If you have a flange that is .250\u201d height, but the material requires that you use a .787\u201d die you won\u2019t be able to bend the part without lengthening the flange.\u00a0 That means you will have to add an operation to shorten the flange.\u00a0 In some cases a wing bend style die or bend strips can allow a somewhat shorter flange to be bent on thicker material but not always and still adds cost of more material and added time to the operation of forming.\u00a0 A good formula is 6x material thickness will be the die size you need.\u00a0 Therefore to figure out if the flange size you had in mind would work you simply multiply the flange length x 2 and then subtract the Bend deduction.\u00a0\u00a0<\/span><\/i><\/p>\n

Production doesn\u2019t necessarily require everyone to complete complex math formulas, but math comprehension is essential to preventing mistakes. In Patrick’s above example, the difference in sizes and lengths for forming and bending material impacts timeliness. Sheet metal fabrication manufacturers will benefit from taking an active interest in their workers\u2019 comprehension of fundamental math concepts and recognize when understanding is or becomes a barrier to efficiency.<\/span><\/p>\n

Cost Reduction in Process Analysis & Attention to Detail:<\/strong><\/p>\n

\"\"Consider contours on the flat pattern of your part. Laser time vs. Turret punch time can have a wide gap in cost. Turrets typically being cheaper for parts that are more straight lines and standard radii on corners etc.\u00a0 Large radius corners means \u201cnibbling\u201d on the punch or moving to the laser. Nibbling leaves more deburr work to have a smooth finish and more hits with a punch whereas the laser just costs more.<\/span><\/i><\/p>\n

Weld fixture.\u00a0 When possible use built in the part feature that self locate and reduce the need for elaborate fixtures to maintain tolerance.\u00a0 Utilizing half shear, flanges, cleco holes (for through hole clamp), and slot and tab configurations.\u00a0 This speeds up the fitting process as well as maintain good quality for less.<\/span><\/i><\/p>\n

Materials and processing require critical thinking and attention to dimension. How do companies evaluate job candidates and existing workers for analytical skills? Employers can gauge a candidate\u2019s capacity for critical thinking by providing a scenario based question in the interview. I recommend offering the candidate the option to answer the question verbally or on paper so that they can give the question full consideration. Ongoing training on process efficiency will also prevent costly complacency pitfalls.\u00a0<\/span><\/p>\n

For an interesting parity discussion, see the following Sage<\/em> article<\/a><\/span> that explores unskilled labor’s impact on construction production performance. Similar issues and concerns exist between manufacturing and construction that emphasize the importance of hiring and\/or nurturing requisite labor skills.<\/p>\n

Conclusion:<\/h2>\n

\"MetalCost reduction in sheet metal fabrication requires specific skills that prevent mistakes and ensure efficiency. Much discussion has revolved around finding skilled workers interested in the manufacturing industry, and this issue remains a concern as younger workers are compelled to 4 year degrees or different professional fields. Thus, a thinner candidate pool requires reconsideration of how to identify and nurture essential skills through the screening process and\/or ongoing job training programs. For more information about alternative hiring programs, check out Meta Fab’s previous article on re-entry programs: NEED WORKERS? RECRUITMENT BENEFITS THROUGH REENTRY & VOCATIONAL PROGRAMS FOR MANUFACTURERS<\/a><\/span>. A follow-up piece that explores how to access reentry programs is forthcoming.<\/p>\n

Programs that offer ongoing manufacturing training skills and job boards:<\/p>\n