Sheet metal fabrication and machine shops, just like all business enterprises, run into diverse conflicts. The problems may consist of the following: maintaining top quality parts, having fair prices, fulfilling acceptable shipment schedules, keeping on the cutting edge of knowledge and technology - to mention a few. A number of steel fabricating and machining shops ...
The Rapid Response Cell - Great for Everyone
Sheet metal fabrication and machine shops, just like all business enterprises, run into diverse conflicts. The problems may consist of the following: maintaining top quality parts, having fair prices, fulfilling acceptable shipment schedules, keeping on the cutting edge of knowledge and technology - to mention a few. A number of steel fabricating and machining shops such as Decimet Sales Inc. (DSI), based in Rogers, a city close to the Minneapolis, MN area, implement a service that is called rapid prototyping. Rapid Prototyping is a rapid-fabricating or machining process that utilizes CAD experts in addition to high-tech CNC machines or metal fabricating machinery to build a physical part in a quicker timeframe.
One obstacle that rapid prototyping shops deal with is production inefficiencies. When a client needs a prototype constructed in a short period of time, long-run fabrication setups might have to be stopped to make room for a rapid prototyping manufacturing project. When that takes place, set-up time for the prototyping project and costs as well as scheduling conflicts certainly will increase. Grievance levels also escalate because now the people operating the machines must stop the long-run production, take apart the machines and get them set up for the prototyping work. Then when that is complete, they must take them apart and set them back up again to complete the long-run projects. It is a laborious and irritating condition because now the long-running project might not be finished on-time or on-budget. Quality and lead times may also suffer. Furthermore, other customer work on the line might not be finished on-time and/or on-budget. This turns into a decline in client satisfaction, a decrease in sales and a decrease in margins.
Short- and Long-Run Manufacturing Issues
What should a Sheet Metal Fabrication and CNC Machining shop do to escape those disheartening conflicts described above? At Decimet Sales, we set up what is called a Rapid Response Cell (RRC). RRC was created to be an self-sufficient work cell with dedicated machinery and workers used for short-run productivity and prototyping work while long-run productivity goes on undisturbed.
To begin with, the RRC was created as an answer to major scheduling issues in the fabrication shop due to pausing long-running production, to provide means for the prototyping and short-run work to be finished. To continue, we needed to eradicate the additional time and costs necessary to re-tool a machine to prepare it for the short-running work. We really wanted to find a method for us to accomplish each type of job smoothly and simultaneously while staying competitive in both production types.
Furthermore, before the Rapid Response Cell, we had conditions in which we were not able to get accurate start and end times due to the regular interruptions that were caused by prototype, re-working, and/or short-running production. Those conditions began causing uncontrollable delivery dates. We were unable to gratify our customers to the measure that we as a company hold ourselves to.
As scheduling conflicts escalated, our owners, engineers, managers and personnel at DSI assembled as a team to share ideas on how to productively correct the problems without causing additional ones in the future. A handful of great ideas were shared from each department of our company and by them, we were able to acknowledge that the Rapid Response Cell was the right choice.
The Rapid Response Cell Layout
The RRC is laid out in a specific section of the shop – one in the fabrication shop and one in the machining shop. Work that has a due date of < 1 week, and < 50 pieces or parts that need re-working are routed to the RRC by way of a distinctive prefix in the project number. Workforce hours are costed the same as the other cells giving customers additional reasons to use the RRC. If and when there are no RRC work orders to do, the cell performs at normal productivity. The RRC can also be utilized for experimental activities, one-off projects, verifying alternative productivity practices or for employee testing.
The fabrication RRC uses a Miller Dynasty TIG welding machine. This is a top-of-the-line leader in TIG welding machines. With 400 AMP AC/DC, pulse, wave form and frequency adjustments, wireless foot pedal and water cooled torch, the welder can handle any metal fabrication prototype production that comes into the shop. The metal fabrication RRC also utilizes a 60-ton AccuPress Press Brake, a Haeger Model 618 Plus PEM machine equipped with Auto-feeder, and a 3,000-Watt Mazak Optiplex Champion Model-3015 Fiber Laser Cutter - Bridge Style that utilizes CNC Mazatrol with Flying Optics.
The machining RRC utilizes a Haas high speed milling machine, a Mazak twin spindle, twin turret, high speed lathe with live tools, grinders, a small drill press and a large inspection table. These all perform excellent for prototype work in the machining department.
The RRC has two full-time employees that man the cells continually, and more can be called on when necessary. The RRCs are also located next to the shipping department which helps to accelerate the shipping process. With this layout, dedicated machines, and special manpower, our RRCs are fully outfitted to complete and ship all quick turnaround projects.
Rapid Response Cell Results
Since the beginning of the RRC, Decimet Sales is realizing rapid growth. We have eliminated all the distractions and interruptions in long-running jobs. Customers are quite satisfied because they have been receiving prototype jobs quicker and giving more prototype, fabrication and machining jobs to DSI. "Stress levels have subsided tremendously" says Troy Brake, Operation Manager at DSI. "Everything is performing more smoothly since the added RRC visibility." Now when workers notice the RRC prefix in the job number, they naturally send it to the RRC and relax knowing that they can proceed with their regular, long-running production projects without giving up time and quality. "DSI should have set up the RRC earlier" added Troy. "DSI would have realized more productivity and an increase to our bottom line."
Rapid Response Cell - It Just Works
Decimet Sales has the equipment and skilled workers that can be assigned to the RRC manner of production. We have the process to maximize work efficiencies. Long-running production projects no longer need to be paused to make way for prototype work. Rapid prototype work can be completed quickly because of dedicated RRC equipment and workers. Stress levels have been diminished along with scheduling issues. To sum things up, RRC means more production in less time and that is a gain for every one. If you require quick prototyping work or short- and long-running fabrication or machining, contact Decimet Sales. We are thoroughly equipped to give you quality and efficient metal fabrication or machining productivity.
