On the Typical Turnaround Time of Sheet Metal Manufacturing Projects

Date:2024-10-04 10:06
The current fierce competition in the manufacturing industry makes it vital for businesses to understand precisely how long their metal parts will take to produce. Metal parts can be made using many different processes; a few of the most common ones are stamping, cutting, and welding. The way these processes are linked together and the way they're timed determine the overall turnaround time for making a metal part.
I. Elements Influencing the Turnaround Time of
Sheet Metal Fabrication Projects
Design complexity
Part design complexity is a principal factor driving project turnaround time. If a sheet metal part is designed with the right number and types of features—bends, angles, holes, and so forth—to mimic a virtually two-dimensional shape, that part will generally service its intended function well. It will also fit into the overall project in an efficient and effective manner. But if the part or assembly is something like the base for a surprise birthday cake, with an irregular surface and multiple flashlight-baking-level curves, fabrication will take far longer than the turnaround time of a flat-surfaced design.
Selection of materials and provision Supply of materials is needed for production. Different materials have different processing characteristics and supply cycles. For example, some special sheet metal materials may need to be procured from specified suppliers, lengthening the supply time. The stock situation of the materials will also affect the turnaround time. If the required materials are in stock, production can start immediately. If the materials need to be ordered, the turnaround time will be much lengthened.
The production process and equipment can elevate the efficiency of production and the swiftness of turnaround. Nevertheless, it is chiefly the apparatus and methods that have a significantly positive effect on those two elements. An apparatus—such as a CNC punching machine—should be operated automatically as much as possible. The same should go for a laser cutting machine. Those tasks ought to be "jobs" for robots or other forms of automatons. Processing should be in the hands of machinery. Processing should not be done by a human with a high school diploma.
The order batch size also greatly impacts the turnaround time. In general, large batch orders can realize economies of scale, and the production efficiency is relatively high, and so the turnaround time may be less. However, for small batch orders, because of the need to frequently change molds and adjust equipment, the production efficiency will be less, and so the turnaround time may be greater.
Ensuring high quality for sheet metal parts requires good quality control and inspection—this much is clear. What is also clear is that good quality control and good quality inspection take time. The quality inspectors for this project are devoted to ensuring that all parts meet the necessary quality standards. Their devotion necessitates three types of thorough inspections: raw material inspection, process inspection, and finished product inspection. The inspectors also have a rework and repair plan at the ready for anything that is found to be lacking. And all of this takes time— a little more, in fact, than was originally allocated to the schedule.
II. The Sheet Metal Manufacturing Project Turnaround Time for Various Degrees of Difficulty
The simplest structures and low process requirements characterize some sheet metal parts, like flat plates and basic bent parts. For such parts, the turnaround time is generally short—measured, under the best of circumstances, in only a few days to a week. To achieve this best-case scenario, you need to have the requisite materials in stock, use advanced production equipment, and have a production process that runs smoothly.
Manufacturing parts of moderate complexity from sheet metal happens at a relatively slow pace. There is nothing to indicate that the parts have a short lead time; they may take one to two weeks to emerge from the production line. We can estimate a specific time within that range by considering the functions and design details of the part itself. If the part's design is on the simpler side of moderate complexity and it's a straightforward bending, punching, or welding job, we can lean toward the one-week estimate. If the part's design is closer to the more complex end of the moderate range, our lean will be toward the more laborious two-week estimate.
For complex sheet metal parts that have intricate structures and demanding high precision, the typical lead time is long. These components—like those used in aerospace applications, for instance—take weeks or months to produce. They must be error-free; anything less than perfection means the component will fail to function properly. Because the structures and features of the parts are so complex, they might well be at the lower limit of what can be achieved through machining. Thus, the parts might be made using one of several possible approaches to fabrication—although any fabrication process probably would have to rely heavily on CNC (computer numerically controlled) operations.
III. Ways to Decrease Sheet Metal Manufacturing Projects' Turnaround Time Optimize design Sheet metal projects must pay full attention to the design stage if they want to minimize lead time. Not only must the design be conducive to the manufacturing process, but it must also be as simple as possible, with as few components and steps as it can manage. During the project design phase, using standard parts and common elements of construction can pay lead time dividends, as well.
Set up a solid supply chain. Form long-term cooperative relationships with trustworthy suppliers. Make sure they understand the importance of timely delivery. Work with them to achieve that goal. Pay special attention to the materials that you use most frequently. And don't let your suppliers hold you hostage. Shorten the MTO turnaround time by as much as possible. And when you can't shorten it, lengthen it sensibly. Finally, take the lead. You are the buyer; make sure you are buying what you need, when you need it.
Put your money into modern production apparatus and techniques.
Introduce cutting-edge equipment and technology, like automated production lines and smart robots, to your sheet metal processing activities. They will augment your production efficiency, cut your labor costs, and tighten your turnaround time.
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