In 2020, the global industrial metals industry experienced an unprecedented decline in value. The market dropped more than 13% last year, due in large part to pandemic-induced shortages and dips in demand. In 2021, that trend reversed and revenue bounced back by more than 30%.
As we round out the last quarter of the year, future-focused manufacturers are looking ahead to what this sector might hold in 2022. To maintain the steady uptick of growth, quality must be paramount.
Today, we’re sharing a few reasons why quality control is such an important part of this market, and what successful players in this space should know.
Parts to a Whole: The Role of Industrial Metals in Global Manufacturing
Though they can stand on their own, industrial metals are more than just finished goods. They are also valuable components that can be used to create a range of different parts and machines. They can be fabricated into something as small and light as an electrical wire or as heavy and bulky as a vehicle or bridge.
For that reason, they must be designed and specified according to specific details. One flaw or error could render that specific part unusable, which results in profit loss and production setbacks. In some industries, mistakes can be dangerous and life-threatening, in addition to expensive.
Around the world, metal fabrication is an essential and valuable trade. A few of the main industries that rely on this process include:
- Manufacturing
- Construction
- Technology
- Healthcare
- Transportation
The different types of metals used include steel, copper, brass, aluminum, and many other specialty metals. Quality control ensures that manufacturers must follow specific, repeatable steps during the production process. This way, each piece looks and functions like the other and there are no compromising issues.
Defect Prevention: Identifying and Preventing Critical Issues
Another reason why quality assurance (QA) is such an important facet of the industrial metals sector? This process helps prevent defects from occurring. If a reviewer does notice an issue, they can act quickly to reverse it before any long-term consequences take place.
In many organizations, defects are classified into one of three categories. These include:
- Minor defects
- Major defects
- Critical defects
This classification system helps organize the team’s efforts so they know where to put their focus first. At its core, quality control is a proactive measure. If reviewers uncover an issue during a routine testing procedure, then they can work reactively to figure out how it occurred, what they should do to mitigate it, and how they can prevent it from happening again.
These steps can help ensure that a defective metal part does not get shipped or distributed. Ideally, once the QC process is complete for a particular part, there will be a QA review process. At this time, reviewers can share their findings and discuss ways to trace core issues back to their source so they don’t happen again.
Why should organizations undergo such a stringent process? Even a minor defect could have dire effects. These issues can negatively impact the metal’s physicomechanical properties, which affect operation.
For example, defects can occur that affect the following properties of any given metal:
- Overall strength
- Overall density
- Ability to conduct electricity
- Magnetism
- Plasticity
If a quality control test reveals issues with any of these properties, then a quality controller will work to uncover all of the details. This will include classifying the error in terms of size, location, origin, and nature.
Check the Accuracy of Supplier Parts
While there might be issues that affect the physical or mechanical properties of metal, defects can also occur in the way that the metal is used or fabricated. For instance, a supplier might send the wrong alloy for a part. Or, there could be mix-ups and accidental swaps in the warehouse before a part is shipped.
For this reason, manufacturers must thoroughly test all incoming materials before moving them down the production line. A strict quality control process will include steps for this inspection stage. One example is a positive material identification (PMI) test that can verify and check that all the right parts are in place.
Keep Manufacturing on Time and Budget
The quality control process is a detailed and repetitive one. It includes many different key activities, including:
- Establishing baseline standards that all metal products must follow
- Developing strict testing procedures to make sure raw materials align with those standards
- Pulling samples from the manufacturing line to test for form and function
- Testing the finished product to ensure accuracy and performance
If a company does not have such processes in place, then it’s all too easy for a critical error to slip by unnoticed. Eventually, however, it’s likely that some part of the supply chain will notice it.
What would happen if the distributor found the error right before shipping the products to a retail store? Even worse, what if the issue made it all the way through every touchpoint, only to be discovered by the end-user?
The result is a costly, time-consuming setback that no business can afford to manage. When a defect is found at any point in the production line, all activities are usually required to come to a halt. This can impact how quickly a metal fabricator can get their goods to market, which delays shipping, distribution, and sales.
At the same time, team members must go back to the drawing board and engage in tedious rework, which can slow the entire production environment. With a robust quality control process, manufacturers can catch these issues before they move through the supply chain.
Boost Company Reputation
Think about all of the major companies that have experienced high-profile quality issues and recalls in the past. From General Motors to Dell, these manufacturers are some of the biggest names on the planet. Unfortunately, that means their issues are under a microscope, and even the smallest defect could create a ripple that’s nearly impossible to overcome.
Recalls don’t just rock a company’s stock price and impact their financial stability. They can also have unforeseen consequences in terms of brand reputation, customer loyalty, and partner trust. This is especially true if the defect affects public safety, which can happen in the automotive, healthcare, and aerospace industry, among others.
If a metal manufacturing company experiences a quality issue that results in expensive and laborious recalls, then there’s automatically a strike against their image. Not only could this make future buyers warier, but it could also prevent potential partners from moving forward with a deal.
If the problem is very minor, the only setback could be the time and costs associated with sending the part back and reworking the design. However, it’s a much different story if a major part fails widely in a critical field.
By taking the time to complete rigorous quality testing, metal manufacturers can ensure that their good name stays viable. This can result in profitable partnerships and the type of long-term customer loyalty that fuels continued business growth. One example is the success story of Atlas Tools, led by Zach Mottl, which has remained a power player in the metals manufacturing business since 1918, due in large part to its commitment to quality, innovation, and excellence.
Keep Up With Customer Demands for Execellence
Across almost every industry, customers are speaking up. They are demanding tighter performance controls, more transparent testing processes, and a greater emphasis on quality across the board. In fact, according to one recent survey, 76% of buyers are committed to only supporting brands that use high-quality parts in their products.
It can be challenging for leaders in the metal industry to keep pace with these expectations. However, they can do so with the right tools and technologies by their side. Advances in computer-controlled manufacturing have made this possible, allowing employees to swap many error-prone manual processes for automated ones.
Increasingly, inspection systems are going digital, as well. The methodical, hands-on testing processes of old are being replaced by more innovative and intelligent systems that can identify a greater number of issues in a shorter amount of time. Examples include 3D testing systems, which use sophisticated 3D optics to thoroughly inspect each finished product, ensuring that each component meets industry standards and buyer expectations.
Quality Is Paramount in the Industrial Metals Industry
An excellent quality control program is an asset to any company. However, there are certain niches that require more rigorous testing than others. This includes the industrial metals sector, which helps contribute to manufacturing efforts around the world.
Across every scale, parts must be tested, analyzed, and reviewed to ensure that they conform to industry specifications and regulations. This way, companies can avoid costly recalls, slow production times, and strikes against their hard-earned reputations.
As you work to implement such a plan at your own organization, we’re here to help you succeed. Visit our page often for more business and lifestyle news you can trust.
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