Manufacturing vs. fabrication
When welding is involved, the distinction between fabrication and manufacturing can be blurred. The manufacturing business usually has different priorities and needs compared to a shop for fabrication. This is due to more than production and size. So, how do you determine whether your business is a fabrication or manufacturing operation?
Take a look beyond the total number of arcs, and consider things like the kind of work that is being done and the method by which it is completed.
Being aware of the areas where you are most closely aligned is a great way to aid in better decisions about choosing the right equipment and optimizing your process. This can allow you to maximize efficiency and save both time and money.
These are four questions to help you decide whether manufacturing or fabrication is the best choice for your needs.
Does the work have a high chance of repeatability?
The main difference between manufacturing and fabrication is the degree of repeatability during the welding process. Manufacturing can be very repeatable, whereas fabrication tends to be smaller volume or projects that are one-off.
However, that doesn’t mean manufacturers don’t have a variety in their components. Manufacturing typically has less mix and a greater volume of product composition. Therefore, even though the final product might differ in appearance, the welding process does not alter significantly.
Most of the time, a manufacturing welding process follows a standard pattern and is usually distinguished by the individual unit of production. The components are delivered to the welding cell, already prepared and ready to be welded, and the components that are produced on different assembly lines are often put together to form a finished product.
Manufacturers usually seek large-scale contracts that have part volumes instead of one-off projects, and welders working in factories typically have more specific tasks.
In all sorts ts manufacturing processes, welding technicians typically require the ability to be able to handle everything from setup and bending, to grinding and welding. This is because the components in a fab shop might be brought to the welding cell, but not prepared to be welded. The shop may receive pallets of parts, including a plan, blueprints of the blueprint, call-outs, as well as weld procedures, as well as the welder may need to install and fabricate at the speed of. This usually will require more in-cell gouging, cutting, tinning or fitting, grinding, as well as tacking to fabricators.
Of course, businesses create parts from all over the world and aren’t able to fit into either the fabrication or manufacturing bucket. A popular industry term used for these companies is “manu-fab.” In general, they’re involved in bigger, more custom-designed projects that require different abilities to complete. They don’t have to face the same issues every day, and choosing the right solution and welding tools could help them overcome these difficulties.
Are throughputs the most crucial measure?
Productivity is a key factor in almost every business, but throughput is often the most important performance indicator for manufacturing. Labor is by far the most expensive cost, and it’s all about keeping downtime to a minimum while also maximizing the amount of time spent on labor, while getting the most items to the market as quickly as you can.
This makes quality and consistency crucial. The time and cost used to rework is an enormous blow to the throughput in a manufacturing facility. The time saved on rework and cleanup after welding results in more value-added time for a welder operating under the cover. Welding with pulse methods is a method that could help reduce the need for rework and lessen the effect of operator variations when it comes to producing high-quality welds.
Although it is true that the caliber of initial weld is important for fabrication, however, these shops tend to be more agile in changing when needed. The amount of throughput is crucial, but isn’t always vital, as a fabrication shop does not have components backing up in the production line for every minute that is spent on a rework project.
Welding Intelligence solutions can assist companies of all sizes and types in evaluating welding activity and drilling down to important information, providing real-time insights into key metrics like welding defects and failed welds.
Does flexibility matter?
Since flexibility on the go is important when working in fabrication, multiprocess flexibility is a crucial aspect to consider when selecting welding power sources.
Fabric shops must be ready to tackle every task that comes i, regardless of whether the materials used in the work are carbon steel or cast iron, stainless, or Inconel. Welding equipment that isn’t able to permit the shop to finish many different tasks is a drawback, while the equipment that can be used to do everything can be a benefit.
The kind of material that will be welded the most frequently is a factor that can help companies determine which machines they will require on the shop floor. The flexibility of a multiprocess machine allows shops to maximize efficiency across a broad range of fabrication tasks.
In manufacturing processes that are highly repeatable, single-process machines that provide the most advanced MIG capabilities are typically more frequent.
Do you have fixturing?
The other major difference between fabrication and manufacturing is the fixing for the welding.
Manufacturing generally utilizes fixturing that is reused for welding in position. However, the majority of fabrication processes do not use fixturing. Welders typically rely on chains, clamps, and other supports to keep pieces in place during welding.
Fixturing or not is a factor in determining the welding process most appropriate for the task. A pulsed or spray transfer MIG can provide significant advantages for efficiency and productivity when it comes to horizontal, flat welding that includes fixturing. A flux-cored procedure can provide various advantages when welding outside of the position.
Be aware of the differences for an optimal process
Are you able to repeat your wo,rk or do you require greater flexibility in equipment and staff to handle a wider variety of tasks? Whatever the case, you’ll need the correct welding equipment and tools to finish tasks efficiently and with top quality.
Understanding the differences between manufacturing and fabrication, the major elements that impact it in helping companies select the best equipment and optimize their welding processes to increase effectiveness.
