Fabrication Cutting, Bending and Assembling

Fabrication is the process of cutting, bending and assembling light metal structures like cabinets, furniture, ventilation ducting, roofing, flashings etc. Lightweight metal is rolled off rolls and usually cut by computer-controlled laser or turret press. The resulting shape can be folded and spot welded and finally powder coated and assembled into the final product. Strength is achieved by use of folds and support rather than a heavy frame. Products such as heaters and whiteware are commonly used in family homes whereas Ducting and Roofing is used in factories and large buildings.

Fisher and Paykel are a large engineering company that manufacture ovens, washers and other appliances and ship them throughout the world. Other engineering companies make heaters, mailboxes, hot water cylinders and a range of other smaller products. Some specialist engineers that produce ducting and ventilation systems also utilise the skills of other specialist engineers like Plumbers, Electrical Engineers, Plastic Engineers, Toolmakers, Design Engineers and CAD/Drafts people.

There are a great variety of skills required in designing, manufacturing and installing these customised products, so there are many career pathways and choices that you have when considering a career in any of these engineering jobs.

Entry into Fabrication

Entry into Fabrication can be through work experience or pre-trade from other non related professions. Practical skills are very important in understanding how objects are made, and later a person can progress to design and management roles as their career develops.

Tool and Die Making

 Tool and Die makers are among the most highly skilled workers in manufacturing. These workers produce tools, dies, and special guiding and holding devices that enable machines to manufacture a variety of products we use daily, from clothing and furniture to heavy equipment and parts for aircraft.

Toolmakers craft precision tools and machines that are used to cut, shape, and form metal and other materials. They also produce jigs and fixtures (devices that hold metal while it is bored, stamped, or drilled) and gauges and other measuring devices. Die makers construct metal forms (dies) that are used to shape metal in stamping and forging operations. They also make metal molds for diecasting and for molding plastics, ceramics, and composite materials. Some tool and die makers craft prototypes of parts, and then determine how best to manufacture the part. In addition to developing, designing, and producing new tools and dies, these workers also may repair worn or damaged tools, dies, gauges, jigs, and fixtures. To perform these functions, tool and die makers employ many types of machine tools and precision measuring instruments. They also must be familiar with machining properties like hardness and heat tolerance, of a wide variety of common metals and alloys. As a result, tool and die makers are skilled in machining operations, mathematics, and blueprint reading. In fact, tool and die makers often are considered highly specialised machinists. The main difference between tool and die makers and machinists is that machinists normally make a single part during the production process, while tool and die makers make parts and machines used in the production process.

Working from blueprints, tool and die makers must first plan the sequence of operations necessary to manufacture the tool or die. Next, they measure and mark the pieces of metal that will be cut to form parts of the final product. At this point, tool and die makers cut, drill, or bore the part as required, checking to ensure that the final product meets specifications. Finally, these workers assemble the parts and perform finishing jobs like filing, grinding, and polishing surfaces.

How Toolmakers Work

Modern technology has changed the ways in which tool and die makers perform their jobs. Today, for example, these workers often use computer-aided design (CAD) to develop products and parts. Specifications entered into computer programs can be used to electronically develop drawings for the required tools and dies. Numerical tool and process control programmers use computer-aided manufacturing (CAM) programs to convert electronic drawings into computer programs that contain instructions for a sequence of cutting tool operations. Once these programs are developed, computer numerically controlled (CNC) machines follow the set of instructions contained in the program to produce the part. Computer-controlled machine tool operators or machinists normally operate CNC machines; however, tool and die makers are trained in both operating CNC machines and writing CNC programs, and they may perform either task. CNC programs are stored electronically for future use, saving time and increasing worker productivity.

After machining the parts, tool and die makers carefully check the accuracy of the parts using many tools, including coordinate measuring machines (CMM), which use software and sensor arms to compare the dimensions of the part to electronic blueprints. Next, they assemble the different parts into a functioning machine. They file, grind, shim, and adjust the different parts to properly fit them together. Finally, the tool and die makers set up a test run using the tools or dies they have made to make sure that the manufactured parts meet specifications. If problems occur, they compensate by adjusting the tools or dies.

Tool and die makers usually work in toolrooms. These areas are quieter than the production floor because there are fewer machines in use at one time. They also are generally kept clean and cool to minimize heat-related expansion of metal workpieces and to accommodate the growing number of computer-operated machines. To minimize the exposure of workers to moving parts, machines have guards and shields. Most computer-controlled machines are totally enclosed, minimizing the exposure of workers to noise, dust, and the lubricants used to cool workpieces during machining. Tool and die makers must also follow safety rules and wear protective equipment, such as safety glasses to shield against bits of flying metal, earplugs to protect against noise, and gloves and masks to reduce exposure to hazardous lubricants and cleaners. These workers also need stamina because they often spend much of the day on their feet and may do moderately heavy lifting.

Companies employing tool and die makers have traditionally operated only one shift per day. Overtime and weekend work are common, especially during peak production periods.

Tool and Die. Top 5 Techniques to Reduce Manufacturing Costs

Manufacturers are always looking for techniques to reduce their cost. Here are five of them that will help the manufacturers reduce cost irrespective of their sector.

The primary step would be to assess their process and do on internal audit. Only when the big picture is at view, methods can be implemented to reduce the costs.

 

 

Cost reduction in Production Process

 

Energy Efficiency

Most of the time without our notice we tend to waste a lot of electricity. Implementing sensors that would stop the machines immediately after usage can reduce quite a lot of cost. Replacing energy guzzling machinery with those consuming less energy can save up to 10% of the cost. Usage of alternative energy sources like solar energy which is the cheapest source of energy can cut down operating cost significantly.

 

Fixed Cost Reduction

Machinery for a manufacturing industry is very important, but only a few machinery are  constantly used. Hence, owning the machinery that is used passively wouldn’t be feasible; renting/leasing such machinery can reduce the fixed cost. Using automation in production process can decrease the labor cost abundantly. Outsourcing advertising, marketing and sales could also help in cost reduction.

 

Overhead Cost Reduction

Maintaining inventory by not over producing and recycling/selling the wastage or scrap of the raw material can always free up and manage the factory space and reduce wastage. At times, outsourcing supply can reduce the business space, risk, staff, maintenance of vehicles. Buying raw materials at bulk and sharing it with another manufacturer can reduce the material and inventory space. Intercom and internet calling, conferencing and video calling meetings can help reduce administrative cost.

 

 

 

Reduction in Labour Costs

Usage of technology for the manufacturing process like implementing sensors and automation, robotics can drop down as the number of labors drops as the automation requires less human interference and is more accurate. Using part time workers and free lancers can eliminate the idle time of laborers. Implementing methods to increase efficiency; comfortable positive workplace, eliminating overtime as it reduces efficiency, training employees, getting to know the employees, re-skilling of the employees rather than assigning them monotonous task can help the manufacturer make optimum use of the labor force.

Customer Related Cost Reduction

Technology can help the manufacturer cut down the cost in every stage of the manufacturing process and also at marketing. Using technology for marketing, advertising and promoting of goods can reduce cost abundantly. Designing products digitally 3D print of the product would help the manufacturer in better understanding of customer needs and can reduce correction and reproduction.

Current scenario of machine tools and enhances workers in manufacturing industry

The ever-changing machine tool market in the country contains a higher potential of astounding growth. The machine tools are a vital part of the industry segment of the country. We can say without an esteemed machine tool industry; the economy of a nation can’t just survive. The discrete manufacturing segments like railways, plastic industry, defence, automobiles and more solely thrive on the machine tool industries in the country. The industries amidst the globe cannot achieve the brilliance without machine tool segment. 

If we talk about the global scenario, we can say not every country is strong in the diverse machine tool segment. The developed countries are great when it comes to innovating the machine tool segment. According to reliable resources, the Indian machine tool industry is set to touch $1 billion USD in the current fiscal year. The higher-end manufacturing segments like Defense and railways rely greatly on these. The medical electronics & he aerospace is garnering the limelight through the esteemed development of machine tool industry. 

Any country can experience substantial high-end growth if they become a key player in global machine tools. In short, the machine tool industry is equivalent to the mother industry. It is imperative to shift the machine tool capacity to a low-cost and a higher skill generation. Talking about the Indian machine tool industry, there are around 150 different major key players in the machine tool segment of the country, the top players account for a significant share in the market trend. The latest trend of obtaining the CE marketing certification by the major machine tool players is crucial, it is done so as to meet the demand of the European markets.

The growth of any industry solely depends upon the growth of its engineering sector. The user sectors of machine tools as stated above derives the life of any nation. To reduce the dependence on the import is a vital prospect, the Indian machine tool industry may offer an opportunity here. Shaping your machine tool industry and projecting the skilled labour is what we need.

In simpler terms, the machine tool industry has been growing in the both volume index and the value terms in the country. The manufacturing of the vital machine tools has been increasing over the period of last three years. Under the various initiatives of the government like Make in India, the industry is booming to its full potential. Over this fiscal gap, the industry has been increased by a whopping 32 percent. If we talk about the volume term growth of the machine tool industry, it has increased by over 7 percent. Machine tool industry requires complex castings and what comes as a great fact is that the India has a deemed foundry industry to aid the machine tool industry in this regard. 

Overall, we can say that the imports have been increased to meet the demand, the machine tool segment needs a constant upgrade to meet the ever-rising demand of the industry. If one wants to cater to a long-term growth then transforming the machine tools industry is what you need.