Plasma pleases plentyTechnological developments in lasers are positioning them as an attractive alternative to plasma. But fabricators are still sticking with plasma cutting for many applications where speed and cost-effective operation are concerns.
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Fabricating technology advancements drive new plate finishing trendsThe same industry forces of nature—globalization, economic conditions, quality demands, and safety and environmental regulations—that are pressuring metal fabricators to do more, better, and faster with less are blowing no less forcefully on finishing fabricators.
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Handling metal stamping wastes: Protecting the environment - - and your businessMetal stamping companies are required to comply with a number of regulations relating to the collection, transport, treatment, and disposal of the wastes they generate. As a result, each company must learn which materials are classfied as hazardous and how to comply with detailed regulations.
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Big steel on the ropes: Consolidation looms for a troubled industryIntegrated steel mills in the U.S. are feeling the heat of foreign competition, pricing problems, and bankruptcies. How long will it be before consolidations start narrowing the field?
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Combating plate corrosion: Improving corrosion resistance through welding, fabrication methods |
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How to avoid getting burned by hot work: Preventing losses and insuring safetyMaintaining a safe work environment in facilities in which hot work, such as welding, is done can be easier said than done. Measures such as preventive safety, safety zones, and fire watches can keep employees safe and worker's comp time down
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Stamp of Approval: Full-court press safety: How to maintain an effective safety program end to endIf you want a safe press operation, look beyond the machinery. Don't be surprised to find the keys to a good safety program well outside the confines of the pressroom.
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Ensuring a plant's electrical system safety: One company's experience with infrared thermographyThis article takes a look at using infrared thermography in the plant setting to detect potential fire hazards. It discusses who can provide the service, what sorts of problems it can detect, and generally explains how the problems discovered when using this technology should be handled. It also uses an actual inspection as a basis for the discussion.
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Assessing cutting and forming machine tool safetyThe expanded breadth of recent standards typically includes the entire life expectancy of machines, the full scope of possible risks, the frequency and severity of risks, and the possibility of harm.
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Proper guarding protects workers: Six steps to focusing on your employees' needsWhen people think of machine guarding, usually they think of devices to protect people from the moving parts on machinery.
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When sparks fly ...This article combines examples of fires caused by inadequate protection from welding with information on heat-resistant textiles and how they can be used to provide that protection.
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Dressing for success and other welding safety tipsWhether we are attending a social occasion or dressing for the job, we all give some thought about what we are going to wear.
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Defibrillators—Should you have one in your workplace?This article explores the facts about AEDs, the legalities surrounding their use by laypersons, and guidelines for implementing an AED program in the workplace.
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Your best safety resource: The FMA/CNA Safety CommitteeDo you know the Fabricators & Manufacturers Association, International™ (FMA)/CNA Safety Committee? If not, you should. They're an excellent resource for guidance on workplace safety issues. And they're the force behind the safety focus on thefabricator.com.
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Making the workplace safe for Spanish-speaking employeesModifying your safety program to address the needs of your Spanish-speaking employees can create a much safer work environment. Here's how one company achieved that goal.
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Having a safe office party |
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Occupational injury and illness statistics: Where does your manufacturing job rank?In December 2003 the U.S. Department of Labor's Bureau of Labor Statistics (BLS) released its 2002 occupational injuries and illnesses data. A total of 4.7 million nonfatal injuries and illnesses were reported in private-industry workplaces during 2002, resulting in a rate of 5.3 cases per 100 equivalent full-time workers. Among goods-producing categories, incidence rates ranged from 4.0 cases per 100 workers in mining to 7.2 cases per 100 workers in manufacturing. These numbers are overall averages of subsets in each major category.
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Gear up for welding |
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Safeguarding machines with an ergonomic spin: The importance of human factors in indstrial safety standardsHuman factors contain elements of psychology, engineering, statistics, and observation. Safety codes and standards often are written based on some aspect of human factors, and it may be critical to have a full understanding of the human factors behind the code or standard before applying the same concept to other equipment.
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Put your money where your mouse is: How to succeed in e-businessTo decrease your chance of failure in e-business, focus on the business issues first and the technology issues second.
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Managers are not necessarily leadersOften we are told that leadership is the key to the success of any business or organization. What is leadership? Is it the same as management? And whatseparates would-be or so-so leaders from world-class leaders?
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Reflection—Getting the most from experienceLeaders, what have you learned about yourself, your employees, and your company in the past year? What were your business blessings? What did you learn about your leadership style or methods? What do you intend to take into the new year, and what will you leave behind?
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New Year's Resolutions: Making them work all year longWhat are your resolutions for 2004? "I'm going to lose that extra 15 pounds." "I plan to exercise more this year." "I'm going to be more complimentary to my staff." "I'm going to be more patient." Or, did you remember the resolutions you didn't keep last year and ask yourself, "Why make resolutions? I won't keep them once I get back to the daily grind."
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Taxing situation: New tax incentives aimed at helping out people like metal fabricatorsMost fabricators aren't knowledgeable about tax laws and don't have time to immerse themselves in tax updates. They're too busy on the shop floor.
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US. DOC Offers Export Assistance: Provided by the U.S. Department of Commerce and the International Trade Administration. |
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Implementing open-book management: A management philosophy for surviving the global economyToday global competitors are literally willing to work for food. U.S. workers want a car, a home, and a college education for their kids in addition to their meals. Reducing pay and eliminating benefits is not an answer for anything but a lower standard of living. The challenge is not reducing compensation but rather dramatically improving productivity. Making owners out of employees is the ticket to that productivity. Open Book Management is a philosophy—a value system.
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When hurricanes come: Dealing with the unexpectedMany people watched with awe as the recent barrage of hurricanes hit the Caribbean and southeastern United States. Charley, Frances, Ivan, and Jeanne caused destruction that totaled billions of dollars and, regrettably, took the lives of many people. We sympathize with all those who experienced Mother Nature's wrath and had their lives turned upside down.
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Beating 'world' pricing: Nu-Way Industries finds the formula to take on competition from ChinaDuring the depths of the manufacturing slowdown that has cost the fabricated metal products sector nearly 300,000 jobs since 2000, Steven Southwell, president of Des Plaines, Ill.-based Nu-Way Industries Inc., faced a depressing challenge from one of his multinational OEM customers??either meet the ??total cost of acquisition? achieved in China or purchase the part from the Chinese supplier, inventory it, and incorporate it into the family of parts supplied by Nu-Way.
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'It's gonna be painful' Metal industry players note little to reassure them in days aheadManufacturers were hurting before September. How do things look now? Well ... they could be better, industry players say.
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Staying lean in a lean economySlow times call for some desperate measures, but losing sight of a lean approach to manufacturing should not be one of them. Take an opportunity that slow times present to evaluate your business and take appropriate steps towards a lean operation.
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Mac's Muse: One potato, two potatoes, three potatoes ... gone! As U.S. steel industry gets its lunch eaten, many parties can share blameA lot of parties can share the blame for what's happened to the North American steel industry, and its going to take effort from them all to pull the industry out of its quagmire. Can it be done? Time will tell.
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Steel industry anything but status quo: Next generation of distributors set to lead wave of changeAs the market demands change, the steel distribution industry will take up the gauntlet and change with the times. Contrary to some speculation, the steel manufacturing industry is neither going away nor reluctant to embrace the innovations necessary to survive.
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Sick at Work?All employees have days at work when they don't feel well. Usually these days are intermittent and can be attributed to a cold or other illness or job-related stress.
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The end of the (welding) world as we know it?: Connecticut may face changes in its vocational-technical welding programsThe end of manufacturing is near for the state of Connecticut, some fear.
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Pinpointing future laser welding marketsAficionados of laser welding technology at times must feel a little like telephone vendors beamed back to 1603. They know almost everyone is going to use them in the future, but getting buy-in today can be like hawking loans at 25 percent-lots of interest and few takers.
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March for manufacturingAs the "jobless" recovery continues, the job cleansing of the U.S. manufacturing base tops 2.7 million. These millions now without jobs remain faceless, statistical footnotes to mainstream media reports about how the recession ended in 2001, production is on the rise, and how job losses are singularly attributable to productivity gains. The outsourcing of the American dream for small manufacturers proceeds unabated.
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A 'bout' with the championRep. Don Manzullo speaks about taxes, steel tariffs, health care, and manufacturing's future.
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Goin' Global: How U.S. fabricators can angle in worldwide watersThe U.S. is considered to be the best consumer market in the world. However, competition for this market has increased as more and more countries have cast their rods in the U.S consumer pool.
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Tips on Lean Manufacturing: How to purge weight from your manufacturing operationAll manufacturing operations need to reinvent themselves to compete in today's marketplace. What can you do to change? Try going lean.
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Tips on Lean Manufacturing: Mastering the stop 'n' go of your shop's work flowMastering the flow of work through your shop is your most important taks if you are attempting Toyota's approach to lean manufacturing.
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Superior Service—Why you need itService can make or break a business. Of the top nine reasons consumers give for buying a specific product, eight pertain to the abilities of the customer service system, for example, responsiveness, technical skill, and professional attitude.1
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Overcoming the skilled labor shortageThe labor force of tomorrow needs to embrace manufacturing today if the industry is going to attract and keep the workers it needs in the future.
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Getting the most for your money: 12 financial tips for welding professionalsThese include the importance of contributing to an individual retirement account, retirement programs for the self-employed, tax-exempt investments, $10,000/year gift tax exclusions, charitable contributions, how much money you should keep in checking and savings accounts, liquidity, and diversified portfolios.
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Overcoming organizational paralysisParalysis – what a horrible thought. What if you found yourself in a situation in which you had partial or complete loss of motion and sensation in your body?
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The future of vocational educationThe death knell is sounding for vocational programs throughout the U.S. Readers who responded "Yes, vocational programs have been cut" to thefabricator.com's recent question regarding the status of vocational programs where they live outnumbered those responding "No, vocational programs are intact" three to one.
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Tuning a piano—making the most of your best resources |
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Budget cuts hit welding hard: Extraordinary effort is critical to welding programs’ survival |
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Shedding light on negativity—Part 1 |
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Is your company a breeding ground for workplace violence?Workplace violence—many of us think about it only when national or local media reports an incident. Most of us probably think it happens infrequently and never could happen where we work. And it's likely that workplace violence victims thought the same thing, before it happened to them.
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Shedding light on negativity—Part 2 |
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Dealing with difficult people: Giving time but saving energyHave you ever felt frustrated or irritated with a co-worker, subordinate, or boss? We've all had the occasional run-in with someone at work. Periodic disagreements, misunderstandings, and faulty communication can lead to frustration. But have you ever met that uniqueperson who causes you extreme frustration every timeyou come in contact with him or her?
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Flatness in coil processing operations: New turns in the leveling processMost flat-rolled coil processing operations use some sort of roller leveling technology. Operations people understand what these machines can do to improve the quality of the product they produce. In the competitive marketplace, customers demand and get more that just flat sheets or slit coils.
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Pairing a servo feed with a pull-through straightener: Applications for noncosmetic stamped partsThis article explores the possibility that servo feeds can be used with pull-through straighteners as opposed to a conventional feed line that uses a powered straightener. Using the servo-PTS (pull-through straightener) can save money on equipment and material. The only limitation may be marking the material so noncosmetic applications are recommended.
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Handling the RushThink delicate: an antique vase, velvet gloves, the sweet sound of string music.Then imagine a typical stamping operation: bam-bam, metal on metal, all day long.
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Appliancemaker reduces downtime with stamping press feed system: Inconsistent feeds caused die jams, inconsistent partsThe Whirlpool Co. builds refrigerators at its facility in Fort Smith, Ark. The company stamps the appliance parts—large and small, galvanized, cold-rolled, and aluminum—on approximately 35 presses. The majority of its stamping presses are straight-side machines, although some are open-back inclinable (OBI), and a few are hydraulic.
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Contract stamper increases die life and draw die productivity: Link-drive presses, value-added services, and employee initiative keep the company competitive |
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Metal stamping and electromagnetic forming: New process improves material formability, reduces wrinklingThis article describes the development of electromagnetic forming (EMF) and how EMF works.
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Hydraulic presses make their mark |
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Cutting die-related costs: Where to look to save moneyDemands for cheaper, better, and faster tooling for stampings and the pace of business continue to escalate. This trend is not going to reverse itself.
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Bending tube with an all-electric machine: Characteristics and capabilitiesThis article discusses the ins and outs of all-electric tube bending machines, discussing the challenges, performance characteristics, and typical options of all-electric benders.
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Automating your end forming operation: How to maximize efficiency in the shopEfficiency, productivity, and quality are focal points for end forming operations, and many manufacturers are looking to automation to improve those dimensions of their businesses.
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Waste not, want not: ArrayArray
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The wrinkle-wiper for tube bends: How to choose and use wiper diesA wiper die is a piece of tooling used in tube bending that helps keep the bend from wrinkling. While there are many reasons and ways to use a wiper die in a tube bending maching, you should also know what types are available, their differences, and how to choose the right one for your application.
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Choosing the right robotic weld cell for your operationYour company's first robot may cause more trouble than expected. This doesn't mean that the robot will not work, but it is a piece of
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Inline gauge control in welded tube production: Reducing conversion lossesReducing scrap when converting strip to finished tube is a huge step in bettering your bottom line.
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Choosing a GMAW machine for occasional aluminum welding |
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Using inverter technology: FAQs about inverter-based plasma cuttersBusinesses feel a constant pressure to gain an advantage and control their processes better. However, the decision to embrace new technology often leaves them feeling vulnerable. In the realm of hand-held metal cutting operations, one such decision is choosing between traditional technology and an inverter-based plasma cutting system.
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Whale watching: A doctor's love of whales leads to a complex welding projectMetal artist James Berry constructed a large whale display by making healthy use of Gas Metal Arc Welding. Here's how he did it, and why.
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It happens 'under the hood': Chicago-area builder of water gardens becomes sculptorRick Walsh isn't your typical artisan, nor are his works typical welding pieces. But his personal evolution as both an artist and a welder illustrate the innovation and persistence of any successful welding operation.
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Riding on the cusp of something great: When Colorado artist's career hits plateaus, he climbs themKevin Robb's sculptures seem to defy gravity, arrest time, encroach space. Each sculpture is a moment freeze-framed; each element seems to be impossibly suspended.
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Art From the Forge: Finding new sources for inspirationThose of you who are busy fulfilling commissions for gates, fences, staircases, and the myriad items that keep food on the table might want to look at artwork created by people whose backgrounds are based in the arts. Metalworkers often are so tuned to traditional designs that they are unaware of a swelling modern movement that could generate new ideas, new visions, and new clients.
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Metal Art Takes on the Fireplace: Jim Truett’s custom fireplace screens are both functional and beautifulMetal art takes on many forms, from wall hangings to picture frames to fireplace screens. Just ask Jim Truett, a district sales manager for Miller Electric Mfg. Co. by day and artist in his spare time from his Huntsville, Utah, home.
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Automated welding for job shopsA robotic weldingsystem represents a significant capital investment for a job shop.
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How to Kill a Robotic Project in Five Easy StepsHow would you like to fail utterly in your quest to modernize your shop with robotic weldingequipment? Look no further—we've got all the bad advice you need right here.
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Setting realistic goals for robotic welding projectsExpecting a robot to solve all of your production problems can inflict the cruel irony of ceating more. If you want your robots to speed up your operation, know what they can and can't do from the start.
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Is robotic welding right for you?: Making an informed decisionThis article examines robotic welding and discusses the considerations behind choosing to use (or not use) welding robots. It answers the questions what comprises a robotic welding installation, what costs are associated, and what industries are best suited for robotic welding.
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Selecting equipment for a robotic welding workcellSo you've decided to automate your welding process. Now it's time to select the equipment that performs the robotic welding. It's critical to take care choosing the appropriate equipment and an integration partner.
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Gas-shielded cored wires find their niche: Suitable applications for flux-cored and metal-cored electrodesGas-shielded flux-cored and metal-cored wires are growing in popularity because the wires are fabricated and can be applied to many applications.
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Don't be a hot dog with heating heads: Tips for safe useSome call them rosebuds, others call them multiflame heating heads, and a few call them heat sticks. No matter what you call torch attachments, this article is a frank discussion about these tools that use oxygen and a fuel gas to make a lot of heat quickly. When used properly, they can make quick work of many heating jobs.
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Spinning your wheels?: Separate grinding wheel facts from mythsGrinding wheels used in welding and fabrication are strong, tough tools, but many in the industry have called them "rocks" or "stones," implying that they're unbreakable.
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Brake Line: Press Brakes and More: Planning to cut corners on safety?Press brake safety is a common sense issue.
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The Brakes: Press Brakes and You -- Whose business is safety? Everybody'sWhat sort of safety measures needed in your shop depends somewhat on your equipment, but making your press brake a safe piece of equipment is largely a matter of old-fashioned common sense.
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Press brakes: the quest for a happy ending: Manufacturers, users hope technology is the ticketScreen some press brake owners and manufacturers these days, and it's like they're all reading from the same script:
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New PC-based controls open path to better press brake utilization: Control improvements simplify operator usePress brake forming always has been a labor-intensive process. Shrinking lead-times and smaller lot sizes demand more frequent setups, which cut into productive output hours and put more pressure on manufacturing efficiencies. Fabricators need to find ways to reduce machine downtime for setup and operator adjustments.
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Repair Brazing: Fixing Faulty Jobs and worn-out componentsBrazing has myriad uses for shop repairs. Knowing what seperates a proper brazing job from a poop one can save you alot of headaches and produce some slick results in the process.
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The business of lasersAs we all know, the laser industry has seen easier times. Economic and market pressures have changed the competitive landscape for laser cutting equipment, and the changes are likely to continue. Both lasermakers and laser users need to adapt to the changes in the laser market, and the companies that recognize and adapt first are likely to be those that succeed.
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Cutting through five myths about modern lasers: The truth behind laser cutting technologyWhether you're operating a 10-year-old laser machine or evaluating the purchase of a new one, staying up-to-date on current laser cutting technology and techniques can be the key to maintaining a competitive edge.
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