The Future of Manufacturing in the U.S.A

The manufacturing industry in the United States is growing by leaps and bounds. As technology changes and allows us to produce items more rapidly, so, too, does the manufacturing industry itself. Comparing today’s industry to the industry of the 1950s demonstrates this clearly; more often than ever, we’re relying on machines like laser cutters and cold saws to help us work with difficult materials.

Although the industry continues to struggle slightly in the face of an uncertain economy, there is hope on the horizon. The future of manufacturing in the U.S.A. is bright; discover why, right here.

A Burgeoning Automotive Industry

Walk through downtown Detroit, and you’ll see the post-bankruptcy effects of a lost automotive industry. The loss of Detroit’s beloved vehicle manufacturing plants hit hard; in fact, it was almost the death of the city altogether.

However, America’s automotive industry is staging a comeback, and it looks like Detroit could very well become part of that comeback, too. Automotive manufacturing lines aren’t decelerating like they were 10 years ago; instead, they’re growing and expanding significantly.

More Manufacturers Staying on Home Soil

Recent assertions by political influencers like Bernie Sanders and Donald Trump have driven home the impacts of companies outsourcing manufacturing jobs to places like China and Mexico. The vast majority of manufacturing companies do this because labor and materials are both far more affordable outside of the country, but a current movement to keep work on home soil via tariffs could change that.

If the POTUS moves forward with his plan, it may become more affordable to open factories here in the United States rather than overseas. This is likely to influence the American manufacturing market significantly, reducing competition for the local market and spurring on job creation, too.

Incentivized Exports

The POTUS and other influencers want to keep manufacturing jobs here on home soil, but that doesn’t mean that you won’t be encouraged and incentivized to work in tandem with other countries.

On the contrary; some people suggest the implementation of a certificate system that would incentivize and encourage exports to other countries. These certificates would effectively come in denominations equal to the value of the export.

Importers would need to purchase these certificates, evening out the trade deficits and creating an environment where the U.S. manufacturing industry is competitive. It would effectively give plants the power to offer lower-cost (and therefore more competitive) products to places like the United Kingdom, Canada, South America, Malaysia, and China.

More Technology in Manufacturing Plants

Despite the fact that more manufacturing will likely occur on home soil, plants are likely to rely on technology more than ever. Cold lasers, pipe benders, and even robotic assembly are all becoming more common, reducing costs in the process and eliminating the need for multiple staff members in the process.

Don’t assume you can rely on machines entirely; nothing could be further from the truth. You’ll still need to hire monitoring and management staff to oversee operations, but the type of employees you hire will shift from blue collar to tech savvy.

For more information about the wide array of innovations in the U.S. manufacturing space, reach out to the team at Quantum Machinery Group today.

Safety Tips for Working with Heavy Machinery

Working with heavy machinery is incredibly rewarding, but it does require a healthy dose of safety and caution. Large machines increase the risk of serious injury when safety measures are ignored. Most workers understand basic machine safety tips like “don’t drink and operate heavy machinery,” but it is often far too easy to overlook other more subtle guidelines.

Whether you’re using a band saw or a forklift, we want to help you reduce the risk of accidents with the following important safety tips.

Always Inspect Your Equipment

When was the last time your equipment was fully and properly inspected? For most manufacturing hubs, the answer should be within the last few days. Some machinery may even require daily monitoring for efficiency and safety issues. You should train your workers to briefly inspect any equipment they use for issues prior to beginning their shift; follow this up with a daily, weekly, or monthly full inspection by an experienced repair or maintenance specialist.

Maintain Machines Properly

This tip falls under the previous tip, at least to some degree, but takes the concept just a bit further. Proper maintenance (whether oiling, replacing bearings, or even replacing old equipment completely) is crucial for overall worksite safety. Schedule in maintenance tasks and have at least one person in management oversee them. If they aren’t getting completed in a timely manner, find out why; it takes just one broken blade or bearing to cause a serious or fatal injury on the floor.

Watch for Blind Spots

Whether you’re using a large saw or a forklift, every piece of machinery requires you to work from a certain angle and position. This increases the chance of blind spots that can block your view and increase the danger. Before using machinery, determine where your blind spots are and do your best to keep them in mind at all times.

Have Communication Rules in Place

Nearly as important as proper maintenance is the need to communicate effectively when handling machines. If your floor is excessively loud, consider granting machine operators hands-free CB radios or smartphones for communication. Enact protocols for communication that support everyone knowing where everyone else is on the floor at all times.

For example, if someone is driving a forklift loaded with pallets, everyone around them should know that the forklift is active and driving around the floor. Safety lights, signs, and announcements can all assist you in achieving this goal.

Make Safety Equipment Mandatory

Last, but most certainly not least, is the need to make safety equipment mandatory. Depending on where you operate, this may not just be an optional tip, it could be mandatory, too. Items like protective goggles when using cold laser equipment or hard hats in fall zones keep your employees safe and reduce the incidence of accidents. Slacking off and letting your staff leave their safety equipment off could put their lives at risk.

If an accident happens and the courts can prove you neglected to enforce safety equipment rules, you could even be held responsible for compensation, too. Don’t take this risk; post rules clearly around the floor and enforce them whenever you see slips.

At Quantum Machinery Group, safety is always on our minds. For more information on enacting safety protocols, or to learn how we stress safety on our manufacturing lines, feel free to reach out to us today.

Main Characteristics of Sheetmetal That You Need to Understand

When you hear the word “sheetmetal,” you likely picture the type of metal used to make heating and AC ducts. That is a very common use of sheetmetal, but there are many other types of sheetmetal that fabricators may use in a variety of different applications. Whether there will be section bending or welding to create specific functionality, choosing the right type of sheetmetal is important.

Sheetmetal Is Steel

While there are times when sheetmetal is very thin and flexible, it is not an aluminum product; sheetmetal is made from steel. This steel is unpredictable and has a great deal of variability, depending on the yield, impurities, and perfections.

The label A36, for example, has a yield strength of more than 36,000 psi. and a thickness of 0.0075 in. This helps fabricators choose the right sheetmetal for their jobs and to provide strong structures. This is also a drawback because the A36 label means at least 36,000 psi, but a 41,000 psi sheet will also be labeled A36, and the increased strength can lead to remarkable differences.  

The more knowledgeable a fabricator is about the characteristics of sheetmetal, the more likely they will produce uniform pieces without a lot of variations and weaknesses.

Measuring and Cutting

Everyone has heard that for precision and to avoid mistakes you should always measure twice and cut once. This is especially true when working with sheetmetal because there is no forecasting software that can predict how sheetmetal will react to various conditions.

Simply put, cutting sheetmetal may lead to a variety of reactions based on temperature, cutting method, and, of course, the steel composition. Taking the time to measure twice and cut once will save materials and working hours.

Math Is a Major Part of Working with Sheetmetal

Not only do you need to know what yield your sheet metal is and the dimensions required for the finished pieces, you also need to know the temperature required for heat cutting and the angles needed for the strongest bends based on the thickness variations. It can be a complex matter to put all of these numbers together to create a functional completed piece.

Working with sheetmetal requires a bit more than a sharp pair of tin snips and pliers. Press-brake operation is a major part of fabrication with sheet metal, whether the end goal is ductwork, car parts, tool boxes or appliances. Data tables and algorithms can only go so far; it requires a metal worker who knows sheetmetal to ensure that the bends and cuts are made in a way that strengthens rather than weakens the piece.

When you’re in the market for sheetmetal tools, a trip to the nearest hardware store won’t meet your needs. Visit Quantum Machinery for all you need to work with metal, from cutting implements to mandrel benders. Whether automation and mass production is your goal or whether you prefer to be involved in every step of the process, there are machines and tools available to help you make the most of every piece of metal.

What to Look for When Selecting a New Plasma Cutting System

Choosing a new plasma-cutting system can be somewhat overwhelming. First, you must decide whether automation is truly the way to go for your business. Then, find the right machinery to meet your needs. There is a chance that a laser cutter will be better for your fabrication needs but, then again, when it comes to versatility and per-part cost, it is often found that an automated plasma cutting system will be the best bet.

When Is Automation Best?

If you are a fabricator, you may find that you need a set and regular parameter of cuts and pieces. This makes automation a great saver of man hours and money. In what instances should a fabricator consider automation?

·         If you find that you are repeatedly making the same cuts and not having to change dimensions, then automation would be a time-saving benefit.

·         If you find that manual cuts require a lot of rework, then a more stable and faster cutting system could be the answer.

·         Having issues with fit-up after manual cuts could mean that you need a more cookie-cutter type production.

·         Having a limited labor budget may slow your productivity, as you have to pay employees to manually cut. Using an automated cutter will reduce your payroll and increase productivity.

·         If your final goal is that of weld-ready parts, then manual cutting is not the way to go. Automated plasma cutting produces parts that are ready to weld.

Automation addresses all of these issues while improving productivity and lowering the cost per part. Speed seems to be the most touted feature of plasma cutting. Compared to waterjet and laser cutters, the quality may be a bit less, with rougher edges and less precision, but, for mass production, the automated plasma cutting system is more cost-effective and efficient.

What to Ask Before Purchasing

Once you make the decision to start looking into automated plasma cutting systems, there are several things that you will want to consider and ask about before you decide on a machine. Will you need a standard machine or a high-precision setup? A knowledgeable salesperson will be able to answer your questions and even provide samples for you to compare. Cut quality should be a major consideration when deciding on a plasma cutter.

You will need to find out about:

·         Smooth cut surface

·         Minimal top edge rounding

·         Top spatter problems

·         Bottom dross evaluation

·         Kerf width options

·         Cut bevel angle

·         Nitride contamination

When you compare a variety of samples, you will be able to choose the best automated plasma cutter for your fabrication needs.

Investment

The initial layout for an automated plasma cutting machine is not small. Basically, you are looking at between $80,000 and $120,000 for a high-precision plasma cutter and up to $80,000 for a standard plasma cutter.  This is one reason why it is very important to decide whether automation is truly a feature that your business needs. If you are considering an automated plasma cutting system versus a laser cutter, then you also have to weigh the cut cost per piece and increased productivity, as well as the amount paid for the system to determine your benefit.  

Contact Quantum Machinery today to find out what cutting system will best meet your fabrication needs.

How to Properly Maintain Your Waterjet System

There are many reasons why people may choose to use a waterjet cutting system. In some instances, the materials to be cut are temperature sensitive and wouldn’t do well with a standard laser cutter. The use of nothing more than a high-pressure jet of water allows for accuracy and temperature control as well as minimizing dust and fumes.

Waterjet systems are used to cut glass, rubber, copper, titanium, stainless steel, and stone, among other materials. A waterjet system is a piece of equipment that requires proper maintenance in order to remain functional.

Unmaintained System Problems

If your waterjet system is not properly maintained, you may end up with some of the following problems:

·         Inaccurate cutting

·         Increased use of consumables

·         Excess water usage

·         Replacement part costs

·         Operational downtime

·         Loss of business

·         Total machine failure

If you’ve invested in a waterjet system, it is important to also invest in preventive maintenance software and plan for scheduled maintenance.

Basic Maintenance

Each manufacturer issues their recommended maintenance procedures differently. Owners and operators need to be familiar with the manual and the procedures for maintenance. Even failing to clean the equipment can cause major problems. All shop workers should be competent in three areas of waterjet systems. The first would be software programming, the second, operating the equipment, and the third, maintenance. There are some waterjet systems that are more complex than others and may require more training in different aspects of maintenance.

Pump and Table

The pump and table have several components, such as seals, valves, swivels, and hoses. Some tables may require lubricant while others do not perform well when lubed. This is where knowing your system and the manufacturer’s recommended maintenance program is important.

Nozzle and Tank

In order to avoid uneven wear, minimize tapering, and extend the life of the mixing tube, it is important to make sure that the jewel orifice and nozzle body are correctly aligned, and that the mixing tube is rotated after 8 hours of cutting. Water quality, filters, and the solids removal system are all part of maintaining a well-running waterjet system. Temperature control is also important in maintaining the high-pressure seals and nozzle assemblies, as water that is consistently run through at high temperatures can damage rubber components.

No matter what company manufactures your waterjet system, it is important that every operator knows how to perform basic maintenance and to configure the settings for longevity and machine accuracy. If you’re counting on your investment in a waterjet cutting system to pay off and allow your business to grow, you have to maintain it to ensure the best performance.

The benefit of using a waterjet system over a cold saw or laser cutter may be negligible, depending upon what materials and accuracy you will be cutting, but, in some cases, it may be impossible to achieve accurate and non-damaging cutting with other tools. Understanding both the machinery and your industry as a whole will help you decide whether a waterjet system is beneficial.  

If you are looking for the best in waterjet systems, visit Quantum Machinery and see what we have to offer to help your company offer the highest possible quality cutting services.