Improving Workflow on the Shop Floor

December 5, 2013 / ,

As customers continue to demand faster delivery, metal service centers have no choice but to optimize every aspect of their industrial metal-cutting process. This means squeezing out any inefficiencies that could be holding up production—a task most managers would admit is a lot easier said than done. While every operation wants to run as “lean” as possible, the challenge is finding the time and resources to identify workflow bottlenecks and then pinpoint the areas of improvements that will have a real impact on the bottom line.

As metal service centers juggle issues like multiple shifts, tight production schedules, and a high product mix, it can be difficult for managers to make any broad efficiency improvements. In fact, many companies don’t even know where to start and, in turn, end up pushing orders through instead of taking the time to reevaluate their processes. While this may work in the short-term, the long-term costs to areas such as quality and even maintenance can be detrimental to the economic health of a metal service center.

While efficiency initiatives are no small undertaking, even a few changes can make a difference. The key is knowing where to start. The following are some tips to help managers improve workflow on the shop floor and, even more so, start on a path toward continuous improvement.




Strategies for Meeting Customer Demands

December 5, 2013 / , ,

Like all segments of the industrial metal-cutting industry, forges must respond quickly to changes in the marketplace. This is even more so the case in recent years. While projections from the Forging Industry Association and IHS Global Insights expect the forging industry to pick up again in 2014, a few rough years have heightened competition not only among forges, but also with companies that offer alternatives to forged components. And that competition isn’t just within the U.S. According to a global industry report from ResearchMoz, an Albany, N.Y.-based market research firm, there has been an upward trend in the outsourcing of forged parts to low-cost countries.

This means that meeting customer demands for both speed and quality are essential, especially if you can’t compete on cost. The harsh reality is that today’s customers expect parts to be finished in half the time they took five years ago—with zero errors. The challenge for operations managers is finding strategies that balance excellence and efficiency, making sure that one doesn’t come at the cost of the other.

In some cases, this will require the use of advanced measurement tools and other technologies that optimize production. However, a white paper from the LENOX Institute of Technology suggests several other ways forging operations can ensure they are meeting deadlines and maintaining a high level of quality. Below are a few highlights from the paper, The Top 5 Operating Challenges for Forges that Cut and Process Metal:


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