From Factory to Field, Quality is Key
Daisy Lilley,
Posted
07/28/2011
The metal roofing and wall system business of manufacturing is
more than rollforming panels. There has to be quality in every
aspect of the corporation, from the front office to the production
lines. There must be a commitment to the business philosophy that
is intermingled in operations planning. Expertise is a
requirement-in design, engineering, fabrication, customer service,
sales and marketing. And without innovation, a manufacturer isn't
advancing to the next level.
Twenty-five years ago, the metal manufacturing industry began to
increase its visibility of metal construction products. Since then,
the equipment, engineering, manufacturing and product diversity
have been enhanced with improved process flows, software, colors,
finishes, cool coatings and design options. These advancements are
the result of the efficiency of the modern production process and
the savvy of the manufacturers that continue to raise the bar on
quality and innovation.
Quality
Manufacturers of factory-formed panels have used technology to
improve quality control while accelerating delivery. They have also
implemented systems to further improve quality and efficiency, such
as LEAN manufacturing and Continuous Process Improvement.
"Since we began to implement LEAN manufacturing and Continuous
Process Improvement methods nearly five years ago, we respond to
customer needs more quickly and execute orders faster by
eliminating waste in the process. It's amazing how our staff
continues to apply their experience to all areas of engineering,
production and delivery. We're all more conscious of being
efficient and green, just like our products," says Jim Andreas,
vice president of operations for Fabral, a Lancaster, Pa.-based
manufacturer of metal roofing and wall systems for residential,
architectural, industrial, commercial, post frame
and agricultural applications.
The Continuous Process Improvement mindset encourages employees
to make changes to their daily practice and responsibilities that
ultimately has a positive effect on the customer. LEAN
manufacturing is more structured and focuses on eliminating waste
in every step, including over-production, waiting time,
transportation, processing, inventory, motion and scrap. All this
ensures customers receive quality products in a timely manner.
Ensuring the high quality of factory-formed panels, however,
begins by purchasing only prime coil and paint. "We have always
used our national buying power to pick the best materials, which
may not always be the cheapest, and be sure no secondary or
rejected products are ever used on our line. This allows us to
maintain the highest quality on a wider variety of products because
we have the engineering capability to manufacture more than one
product at a time to meet a variety of customers' needs," Andreas
notes.
The emphasis on quality in purchasing and manufacturing
transfers to quality on the finished project. Choosing a company
that has a track record for quality and a long-term support system
for its warranties is essential for both contractors and
architects.
Sustainability
As more building owners and municipalities make high performance
and sustainability standards integral to their projects,
contractors need to be in line with those expectations and know
their options.
Contractors also need to address how efficiently the product is
manufactured, any on-site construction waste that might be created,
logistics and any other green benefits the manufacturer might
offer. Most of these are solved by working with a national
manufacturer with multiple locations nationwide. Fabral, for
example, has multiple facilities in North America featuring diverse
product offerings. Then, by having panels made to exact
specifications by the manufacturer, contractors help eliminate
costly construction waste and help reduce installation time. In
addition, a company such as Fabral incorporates sustainability
practices, such as: recycling scrap; utilizing energy-efficient
lighting; optimizing freight logistics; and ordering product
support materials printed on Forest Stewardship Council certified
paper.
Support
To make certain the panels are designed and manufactured to meet
project specs, contractors should be able to access a team of
highly skilled engineers. They know the products and warranty
specifications, as well as have field experience.
The engineers are part of a much larger team offered by most
panel manufacturers. And while field rollforming equipment has
improved and offers more features, engineering experience is
essential to meet the unique needs of each project.
"The alliance of our knowledgeable engineering team and seasoned
sales force puts Fabral in a unique position to serve customers
large and small, and provide on-site field support and technical
advice. The training and sophistication of all our employees adds a
professionalism to the services we provide and our customers'
projects in the end," Andreas says.
With a 40-plus year history in the industry, Fabral is an
example of a highly responsive business with solid relationships
with industry-leading suppliers, such as U.S. Steel and Valspar.
These industry relationships help meet customers' needs quickly as
part of a well-running supply and support network that offers a
unique combination of benefits for contractors.
Daisy Lilley is marketing manager for Fabral,
Lancaster, Pa. Visit www.fabral.com for more information.
www.fabral.com