Lean manufacturing isn’t new to the A.R.E. Manufacturing team. For decades, we’ve evaluated our methods, considering how to streamline operations and produce better customer outcomes. One of the most effective “Lean” initiatives we developed is our “Machining-by-Number” system.
Inspired by the paint-by-number kits we used in childhood, “Machining-by-Number” adeptly streamlines our processes, offering us greater agility in exceeding customers’ quality standards and meeting tight deadlines.
We’ll introduce you to “Machining-by-Number,” explaining how it came to be and evolved before delving into its advantages for our customers.
The Making of Our “Machining-by-Number” Program
The A.R.E. Manufacturing team didn’t develop the idea for our “Machining-by-Number” system overnight. This program emerged from our years-long process of introducing and embracing Lean Manufacturing principles. We first adopted Lean approaches in 2005 to analyze our processes and think critically about streamlining them.
Over a multi-year effort, we developed our “Machining-by-Number” program into the robust system in place today. Here’s what we accomplished:
Streamlining Processes with Dedicated Tooling
The challenge: Day after day, our teams played hide-and-seek with tooling, a fool’s errand that was more frustrating than fun. It seemed like every time a team member needed a specific tool, it was never in its proper place. This prompted our leadership team to ask: “The tools are set up and working properly, and we know we’ll need this tool configuration again… Why are we tearing it down when it would be cheaper and more efficient to leave it set up?”
Our solution: Questioning this led to the inception of our dedicated tool process. We’ve labeled each of our cutting tools and tool holders with a number to simplify and shorten each trip to the tool closet. Additionally, we’ve ensured each tool has its designated space, so our team members can easily find it every time.
Documenting Our Processes
The challenge: As our team adopted a designated tooling procedure, we knew we needed to track our processes to improve our setups. Through rigorous, thorough documentation, we capture knowledge that would otherwise be lost or trapped in one person’s brain.
Our solution: When working through a new part for the first time, one of our Level 3 machinists facilitates production from beginning to end. While doing so, this expert documents every tool and process, recording each nuance with attention to detail. Recording this knowledge in our system means the next time a team member goes to set up and run the part, they simply have to follow the clear-cut instructions left for them.
Inspecting Quality on the Shop Floor
The challenge: Initially, we operated like most shops, with a machinist producing the part and sending it to the Quality Assurance department for first article inspection. However, once we successfully developed our “Machining by Numbers” program, we discovered that these quality inspections should occur on the shop floor alongside the person who built the part rather than in an office away from the source.
Our solution: Rather than bringing parts to our quality team, we bring our quality team to our parts. With the QA team on the shop floor, they can facilitate inspection and quality checks as parts are being machined rather than serving as a final line of defense before delivery.
How Our “Machining-by-Number” System Benefits Our Customers
“Machining-by-Number” doesn’t just simplify production on our end. It serves our customers in the following ways:
Enhanced Quality
Moving quality inspections onto the shop floor makes quality everyone’s responsibility, so the onus isn’t just on the QA team. With our quality assurance team monitoring quality during production and machinists checking their parts during each process, our team catches potential risks at the source rather than waiting until the end, when it’s much more difficult to mitigate issues.
Reduced Setup Times
Because our documentation captures all tooling and programming information, we can quickly set up machines and tool configurations. Our swiftness in setting up and producing parts has allowed us to maintain an on-time delivery rate of 97%.
Agility in Supporting Expedited Orders
Implementing the “Machining-by-Number” system has made our team more nimble. This has allowed us to take on customers’ expedited orders, handling fast turnarounds to meet tight deadlines. Best of all, we can fast-track customer orders without impacting our other customers’ production schedules.
Consistent Results from Designated Machinists
At many shops, parts get passed from one person to the next before ending up in quality assurance. At A.R.E. Manufacturing, the same machinist who begins a project handles it during each production stage. Having the same hands and eyes on the part and thorough documentation of each process ensures no details fall through the cracks.
Steady Production Through Strategic Hiring Solutions
Our documentation process and “Machining-by-Number” system allow Level 3 machinists to transfer their tribal knowledge to others within the organization. This paves the way for machinists-in-training to use this captured information to produce components with the same level of expertise as their more seasoned counterparts.
This system has been integral to managing how our team hires and trains staff. Rather than over-exerting ourselves in hiring highly experienced machinists, we’ve emphasized the importance of leveraging this program to train machinists.
How does this expedited training program benefit our customers? They never have to worry about hiring shortages that create gaps on the shop floor and delay production schedules. A.R.E. always maintains a talented workforce, creating a positive ripple effect on our clients.
“Lean” Precision Machining from A.R.E. Manufacturing
At A.R.E. Manufacturing, we simplify the complex, turning challenges into streamlined solutions. Our “Machining-by-Number” system has allowed us to meet customers’ lead times with flexibility without sacrificing quality.
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