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Quality Management Drivers and Solutions

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Today’s end consumers demand quality, and they are quick to try a competitive product when disappointment hits. For manufacturers, the quest to achieve less variability, more consistency and enhanced customer satisfaction has never been more critical. To consistently produce high-quality products, the key is to improve standards of quality control throughout the manufacturing process, and that requires an effective quality management system with the ability to oversee all activities and tasks that must be accomplished to maintain the desired level of excellence. Such a system helps manufacturers identify potential issues and rectify them before they escalate, leading to improved customer relationships and company growth as well as greater productivity and cost efficiencies.

Quality Driving Factors

  • Customer retention – Given that it can cost up to five times more to acquire new customers than to retain existing ones, customer retention is a top priority. Ensuring high-quality standards and delivering consistent standards go a long way towards keeping existing customers.
  • Compliance – For manufacturers, compliance entails complying with the ISO 9001 standard which helps drive quality management practices in metal fabrication. ISO 9001 helps companies improve quality throughout the operation from development and material sourcing right through to product delivery and customer interaction.
  • Product recalls – A product recall is something manufacturers try to avoid at all costs. Statistics show that 25% of consumers reported being less likely to buy products from a company involved in a recall and 65% of consumers said they would be less likely to recommend a company following a recall.
  • Continuous improvement – Continuous improvement is a systematic approach to consistently enhance processes, products (such as water tanks), and services over time. It involves making incremental and sustainable changes to achieve higher efficiency, effectiveness, and quality. By fostering a culture of continuous improvement, businesses encourage employees at all levels to identify problems, suggest solutions and implement small-scale changes to optimize operations.

ERP – Implementing Quality Management

One of the most effective ways of getting quality management right is by implementing an ERP solution that provides the data, tools and infrastructure manufacturers need to gather insights, make informed decisions, and continuously refine their operations to achieve higher levels of efficiency, quality, and competitiveness. A good ERP solution is geared towards helping manufacturers set quality criteria against the products they buy and manufacture to ensure any inputs and outputs from their production lines conform to these standards. This is especially important in today’s competitive market where data is one of the top 3 manufacturing technology trends. Businesses can no longer rely on manual processes and tools to manage quality; it is simply too important to leave up to chance. On the question of customer retention, for example, manufacturers need to manage customer complaints as effectively as possible. An ERP system should provide the tools needed to log, collaborate on, escalate, and resolve customer complaints quickly and smoothly. That way, manufacturers and structural steel fabricators can quickly turn the situation around and build up data at the same time. Similarly, an ERP system with recall management capability enables manufacturers to recall products that are serial or lot traceable. With access to real-time information on affected customers, sales orders, Work in Progress jobs, suppliers and purchase orders, manufacturers can quickly ringfence the problem and stop it from spreading. Effective product recall may be a last resort in the realm of quality management, but it is a crucial one.

Closing Statement

Creating a strong quality management process is essential for manufacturing companies. Not only can it help avoid regulatory fines, good quality can also ensure that the firm is meeting customer expectations and drawing repeat business. A fully integrated ERP quality management system helps manufacturers improve quality performance by reducing variability and costs while ultimately improving customer satisfaction. As the saying goes, there is no substitute for quality – and manufacturers need to always abide by this!

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Rivelin Showcases Post Processing Technology

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Rivelin Robotics has released a video showing its Netshape Robots in action in advance of the Formnext 2023 event. The video shows how the company’s automated metal additive manufacturing (AM) post processing technology works, and emphasises the simplicity of the solution from a user perspective. In particular, the company specialises in the creation of several metal AM post-processing cells, including the NS0, NS1, and NS2, all of which feature robots from their partner, Yaskawa Europe, expertly controlled by Rivelin’s cutting-edge Netshape software. The NS0 cell serves as an affordable entry point for those looking to explore and experience state-of-the-art digital manufacturing  and steel fabrication software. Equipped with advanced Netshape control, sensing capabilities, and instructional features, it offers an ideal platform for digital manufacturing exploration.

The NS1, featured in the video, is tailored for those making the transition into full-scale production. It adeptly manages metal fabrication techniques such as cutting, finishing, machining, and blasting. With its dual finishing zones, it enhances efficiency by enabling simultaneous finishing on one side while loading and unloading on the other. With the ability to handle parts weighing up to 600 kg and dimensions of 800mm x 650mm x 600mm, the NS1 is versatile and compatible with a wide range of applications. The NS2 takes the capabilities of the NS1 to the next level by seamlessly integrating 8 + 8 axis parallel processing. This advanced feature harnesses the power of two robots working in harmony, enabling tasks such as inspection, handling, pick and place actions, fixturing, cleaning, and concurrent machining.

The NS2 offers unparalleled efficiency and precision, making it the preferred solution for those aiming to optimise productivity and finesse in their operations. Rivelin CEO Robert Bush explained, “Our cells as seen in the recently released video are effectively enclosed micro-factories that combine an industrial Yaskawa robot equipped with an array of tools, state-of-the-art sensors and processes to ensure dexterity and driven by the powerful NetShape® control software that we have developed.” Bush explained that their intelligent software leverages a combination of machine learning and traditional deterministic control theory to enhance the quality and consistency of support removal and finishing. This culminates in an automated solution for support removal and finishing of processes like pipe fabrication, which can achieve a 90 per cent reduction in part defects, leading to substantial cost savings and helping to resolve labour shortages like cobots helping to fill Australia’s welder scarcity. The company will be showcasing its innovations at the upcoming Formnext 2023 event, slated from 7 – 10 November. Visitors to the event can find Rivelin in Hall 12, Stand E41, where Netshape robots will be in action. The Rivelin team will also be available to explain how their automated AM post-processing solution has the potential to address various industry challenges faced by metal parts manufacturers through intelligent automation.

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Growth of Medical Manufacturing in Australia

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Australia has an expanding medical manufacturing industry with pharmaceutical giants such as Astra Zeneca, CSL, GlaxoSmithKline, Merck, Novartis, and Pfizer engaging Australian contract development and manufacturing organizations (CDMOs) in development of therapies. It has been setting global standards for innovation and quality and its medicines are much in demand. Medical manufacturing is part of Australia’s diverse and dynamic manufacturing sector which has been growing in different areas and making quality end products. It leads to the question – what is the secret sauce which enables Australia’s manufacturing to be so highly regarded? Let us explore this question further in this blog.

Support from Government

The Australian government has been facilitating conditions for growth, innovation, and further investment in medical manufacturing. Making medical products and medicines requires state-of-the-art, skilled, advanced manufacturing and sheet metal fabrication processes. Governments and industry must work hand in hand to make the most of the opportunities. The Liberal National Party’s Modern Manufacturing Strategy, developed in close consultation with industry, set a solid foundation to build up Australia’s industrial base. The Coalition’s Modern Manufacturing Strategy provided a long-term vision to support the scale and competitiveness of medical manufacturing. It outlined opportunities for Australian businesses based on strengths, emerging industry trends and market potential. A roadmap was laid out on how industry and government, together, could capture opportunities and address barriers to scale. This plan was backed with investment to support companies that want to grow their manufacturing locally. Building up Australian medical products and medicines manufacturing requires specific things from governments: they must ensure they build a skilled workforce so the sector can commercialize technologies and advanced manufacturing capabilities. Governments are the main customers for many medical products so government procurement must function well so that SMEs have the opportunity to provide services and products.

Asian Market and Complementary Medicine

Demand for health therapeutics in Asia is growing in line with its ageing population. The share of the population aged 65 years and over is expected to increase by nearly 2.5 times in the next decades. Treatments for the two leading causes of death – cardiovascular disease and cancer – will be welcomed. Australia’s proximity to and close business ties with Asia offer trade opportunities, including trade benefits as a result of steel manufacturing. Medicines manufactured in Australia can be exported across the region. Australia has free trade agreements with Asia’s largest economies, including China, Japan, and Korea, as well as fast-growing ASEAN countries. Australia also has strong relationships with Asia’s leading universities and research institutions, opening up possibilities for R&D collaborations. As the booming populations of south and south-east-Asian middle classes grow, Australian-made medical products should be their first port of call.

Australia are world leaders in manufacturing complementary medicines. They are known for great produce, innovation, and quality-assured products — this is doubly so in medicine and preventative health. Complementary medicine manufacturing is a high-demand and high-growth industry. The medical products and medicines sector today supports 30,000 workers across the supply chain, and more than 2,500 manufacturing workers. It is a sector that needs to hit the highest of benchmarks for quality and safety. However, globally recognized regulation needs to balance safety and trust with market access. Government must support businesses as they navigate new markets so they can compete globally.

Final Thoughts

The medical manufacturing sector has been a priority for Australian governments and this approach is expected to continue in the future. The government is expected to announce further grants and incentives to heavy steel fabrication companies to support medical manufacturing and partnerships and collaborations are predicted to grow as well. A highly developed medical innovation ecosystem is to be leveraged on the back of Australia’s strong manufacturing base – and the future looks bright for this sector!

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Train Jack System for Perth Metro Meets Deadlines

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Vector Lifting and Bonfiglioli collaborated last year on a 15-month installation for the Perth Transport Authority (PTA), successfully delivering a high-performance lifting solution to deadlines. The PTA had introduced a new fleet of trains and opened a new maintenance facility in Perth which needed 24 lifting jacks to be installed for the Perth Metro Network. Vector Lifting was awarded the tender for the supply and installation of a turnkey jack system, which elevates the train body off the track so the chassis and wheel set can be inspected, repaired, or exchanged as part of quality management. “This a new train with new requirements,” says Clinton Capelli, Mechanical Engineer, Vector Lifting. “Our jacks are synchronised and run through a controlled PLC system to lift all 24 jacks at the same time, same speed and to the right height.” “One of the reasons we were selected for this steel fabrication project – besides the fact that this is a highly specialised application – is that we are a local specialist manufacturer and are competitively priced,” adds Capelli.

To complete the jack system, Vector Lifting sought gearboxes from its long-time supplier, Bonfiglioli. “We have developed a good relationship with Bonfiglioli because we believe in their product – it is robust and reliable. Bonfiglioli’s short lead time and rapid manufacture of custom gearboxes is ideal. They always offer us very good product and technical support, and understand the pressures of our business,” says Capelli. Bonfiglioli supplied Vector Lifting with 24 A Series helical gearboxes in one consignment, ensuring that Vector Lifting would meet PTA deadlines in spite of the pandemic’s challenges. “Bonfiglioli offer local stock and assembly and, for large orders which may require an import, they achieve a quick turnaround because of their wide international footprint and manufacturing set-ups,” says Capelli.

Fred Whalley, Bonfiglioli’s State Sales Manager, says the A Series is suited to the jack system design so it required minimal adaption.  “The helical bevel gear units offer a wide torque range and high efficiency in a compact and durable design,” says Whalley. “This enables smooth, easy handling of goods, even under the most demanding conditions. We have a large local stock holding but in the case of larger orders we can bring them in from Italy in a very short period.” Vector Lifting and Bonfiglioli have collaborated for 22 years. “Vector’s is a tried and tested model – they always order the right product for the application,” says Whalley about the Australian job crane specialist. “They boast a professional engineering team which is well-versed in the principles of mechanical engineering. We enjoy working with them.”

The pairing with Bonfiglioli has benefited Vector Lifting, in return. “Customers choose our products because we collaborate with Bonfiglioli and other suppliers which help us deliver a good product that can stand the test of time,” adds Capelli. “We feel that Bonfiglioli mirrors what is important to us in their own company ethos and how they interact with customers.” He points to the gearbox supplier’s comprehensive customer support offering, which benefits Vector Lifting customers. This is a prolific partnership, with plans underway for further collaborative projects. One is the roll-out of specialised winches (fitted with Bonfiglioli gearboxes) across several West Australian mines using mining plant and equipment, to provide functional and safety enhancements. “We are also in the process of designing specialised lifting equipment for other international rail operators,” concludes Capelli.

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Reducing Steel Scrap in Manufacturing

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During the manufacturing process, the cost of raw materials is usually the most expensive for any industry. Hence, when a high volume of raw material is rejected, it can adversely impact a company’s profit margins. Review of the rejected material (called scrap) is critical and programs to reduce scrap are almost always part of manufacturers’ continuous improvement initiatives. But what is scrap and how can scrap be reduced in the context of metal fabrication and manufacturing industries? This will be covered further in this blog.

What is Scrap?

Manufacturing scrap is the unusable material from a manufacturing operation that will be discarded. Scrap can be subdivided into several categories while used as a general definition for all rejected material. First, there’s scrap that is rejected in raw material form. It may be due to spoilage, or it may be due to off-specification performance characteristics such as tensile strength or shatter point. This material has no additional processing or partial processing added to it. Second, there’s scrap that has been partially processed. Many manufactured goods are produced in stages of a production process, and the failure at any one step can mean that the part must be rejected as part of quality management of metal fabrication. This is more expensive than scrapping raw material as the partially finished part has had some value-added labor. Third, finished goods must be scrapped due to failure to meet specifications. Some can be reworked by adding labor to adjust the part or turn it into something else. Others may require complete scrapping if no rework can be performed.

Ways to Reduce Scrap and Rework

  • Conduct Process Audits: Conducting process audits is the first step in any scrap reduction process. Without understanding the current process as it occurs, identifying scrap points would prove impossible in structural steel fabrication.
  • Improve Communication and Change Management: Manufacturing is a fast-paced, noisy, and extended process. Communication is sometimes non-existent between upstream and downstream processes, and errors can be compounded as a result. The same is true for hand-written notes and tags, where handwriting quality, lack of clarity, and other shortcomings can impact the next production stage.
  • Review Material Sourcing: The quality of a manufacturer depends not only on the quality of material and components used to make goods but also on the quality of material used in industrial processes, such as heat induction bending services. In the case of the former, a rigorous selection of materials such as tensile strength, alloy consistency, and vendor’s production methods can make or break a company’s quality when those materials are in production. In the latter case, cutting dies, routing heads, and other hardened tool types must be guaranteed to cut the material they claim to cut. If the performance characteristics of the tool are inferior, scrap can result.
  • Document the Right Things: Many manufacturers are drowning in written documents from manual procedures. But when it comes to the most critical aspects of documentation, they are lacking. Design iterations for active products should always have defined and traceable access. This includes CAD and CAM drawings and any other engineering specifications.
  • Evaluate Maintenance Strategies: Scrap occurs at a higher than desirable rate while using preventive methods, and most manufacturers have yet to move beyond them. This is because manual condition monitoring requires a lot of labor, manual checking, and measurement of temperature, wear, abrasion, and more. Tool-wear and failure may not be detected with a manual preventive maintenance strategy, and data may be omitted through error, bias, or training issues.

Curtain Call

Scrap is a necessary evil, however there are many means to reduce scrap in fabrication and manufacturing processes. It also requires a change of mindset to move towards sustainability in the steel manufacturing industry and management involvement may be required. So, the goal of companies should not be to make the “scrapyard” empty – but to ensure that lesser scrap is sent to the “scrapyard”!

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Quality Management for Metal Fabrication

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Think of a scenario where a client has contracted out a pipe fabrication project to a vendor. At the end of the project, the product delivered to the client did not meet expectations. What went wrong here? The short answer is quality – defined by ISO 9000:2015 as the “degree to which a set of inherent characteristics of an object fulfills requirements.” – was compromised. Quality is usually the yardstick by which the competency of fabrication companies is judged. There are varying degrees of quality, hence if a fabrication company mentions that it makes “quality” products, further details will be required. This blog will look to provide more insights on this topic.

How Is Quality Measured?

Quality is an essential requirement for a structural steel fabrication product and a fabricator needs to have a robust quality management system in place. A QMS is made up of several components, two of which are quality assurance and quality control. QA focuses on providing confidence that quality requirements will be fulfilled. This component works to prevent errors through quality policies and processes. However, having confidence isn’t always enough, as no system is foolproof. That is where quality control or QC comes in as it focuses on finding and correcting errors before the parts get to the customer. Beyond receiving a product that meets customer requirements and expectations, a formal QMS provides additional value that leads to a positive return on the metal fabrication investment.

Maintaining Consistency and Improving Cost Effectiveness

Consistency is a cornerstone of a solid quality management system. If the customer receives products that are within spec sometimes and other batches are out of spec, the fabricator likely does not have a strong quality system in place. A QMS is designed for manufacturing process improvements, ensuring increased efficiency and operational excellence. Automation techniques for fabrication are standardized to improve repeatability for even the most challenging projects. QC checks ensure quality remains consistent from batch to batch.

A successful QMS also innately controls costs. Defective parts can result in scrap and rework, adding unexpected costs to solve. This can also add time to project schedules, creating delays in processes or getting the product to market, resulting in lost revenue.

Ensuring Compliance and Reducing Hazards

Most fabricated products must meet safety, performance, and/or regulatory standards. For instance, products used in the food and beverage industry must meet the requirements of the USDA or FDA for food contact. Many customers may require 3A sanitary standards to be met as well. Other industries, such as aerospace and defense, have tight tolerances for parts and may require a manufacturer to be International Traffic In Arms Regulations (ITAR) compliant.

Defective products can be a safety hazard. An effective QMS has checks in place to anticipate a potential problem before it becomes a safety hazard in metal fabrication. If the product carries an inherent risk where failure could result in catastrophic results, ensuring the fabricator has a string quality system is no longer a nice to have; it is critical. If the product is used in the workplace and is found to be defective and there is an accident, OSHA fines may be levied.

Conclusion

Quality can lead to far-reaching effects on customer relationships. When the parts are coming from a metal fabricator that values producing high-quality parts consistently, customers will depend more on the fabricator to meet their needs. Conversely, poor-quality parts will reflect badly on the fabricator and tarnish its reputation in the market. In an increasingly competitive metal fabrication industry, quality management (or the lack of it!) will be the sieve through which poor fabricators are filtered out!

© K999 Engineering & Construction Co. Ltd. 2023