Perspectives on Plating and the Metal Stamping Process

For many of our jobs, the question of plating comes into play – there are a variety of different options out there in terms of specific techniques or metals that correspond to different desired outcomes for the final product.  As a custom metal stamping business, we don’t do plating ourselves, but we often do jobs that either require post-plating or stamp pre-plated pieces, and we’ve identified some key issues to be concerned about when considering when in the process to plate your piece, and thought we’d share what we’ve observed. 

As we mentioned earlier, the two options we come across most are stamping pre-plated material, or sending off the stamped piece to then be plated.   There does exist a third option called partial plating, presumably a cost saving measure designed to be compromise between the advantages of the two.

The advantages of pre-plating are pretty straightforward – the cost tends to be lower, and there is less opportunity for dimensional issues in the finished product.  Plating is of course adding a layer of another type of metal onto the work piece for either corrosion resistance, conductivity, aesthetic or other purposes, but as a function of the process, it can create dimensional issues that need to be taken into account, depending on the tolerances desired for the part.  This is where using pre-plated material can be an advantage, as that process has already been performed, and won’t factor into the final stamped dimension. 

However, as a function of the stamping process, a pre-plated part won’t be 100% plated after stamping, so for applications where perhaps there is exposure to a harsh environment, or the part is visible and a seamless finish is preferable, post plating may be desirable.  Again, this is typically the more expensive option, and with the added handling of the pieces, there is an increased possibility for dimensional concerns to arise. 

As with many design and manufacturing considerations, the key is to identify which factors most affect the characteristics of the final product that are most important, and make the decision based on those variables.  The benefit (and we would say the beauty) of being a custom manufacturer is that we have the experience and capability to cater to whatever peculiarities the job requires.

Manufacturing in the Global Environment

We’ve talked much about the American manufacturing industry here on our blog, but one thing that transcends national borders is environmental consciousness.  Within manufacturing, and on a global scale, a key concern for many responsible businesses is the objective to operate in a way that impacts our environment the least, and demonstrate an awareness and attentiveness to how the processes of production are regulated and managed, to optimize efficiency and minimize waste.

The organization that provides the global standards and certifications is ISO, and the particular series of certifications concerning the environment is the 14000 series.  Last month, Keats again passed our ISO 14001 inspection and received our certification, something we’re quite happy about and proud of.   This certification covers many responsible business practices throughout our facilities, from the offices to the factory floor.  With considerations as broad as light-bulb types to spill-containment procedures, the certification ensures that energy management and environmentally sound practices are employed. 

As awareness and concern for proper environmental practices grows, we at Keats want to be on the leading edge of reform, implementing and encouraging realistic approaches to energy management and environmental responsibility.  We hope you agree, and will continue with us on the road to an eco-friendly future.  

Keats and Customer Service

Being committed to customers is something that every business, from big box retail to local coffee shop touts as their highest priority.  It’s no secret that customer service has become of utmost importance for business success, especially as the internet is increasingly empowering customers with reviewing platforms like Yelp, Angie’s list, or Merchant Circle.  One major way that customer service can be seen in the manufacturing industry is the concept of just-in-time delivery. 

         

Just-In-Time is a business philosophy, the inception of which is largely attributed to the Japanese auto maker Toyota, and is a primary practice associated with lean manufacturing.  Just-In-Time is a logistics technique that aims to control inventory in such a way that reduces or eliminates the warehousing of unnecessary product, but maintains an accurate and predictive schedule of supply so that the proper amount of product reaches the proper place “just in time”.  This streamlining of inventory can reduce lead times, cut down on expensive warehousing needs, and limit overproduction and overstocking, so that many businesses are protected.  What is required for an effective system, however, is a vendor that has the utmost concern for quality control, and the means to deliver the product on the precise schedule determined by the data collected.

In both of these, Keats can be seen to have a strong and ongoing commitment.  Originally opened as a storefront shop in northwest Chicago, our dedication to provide our customers the best quality products on the best schedule has necessitated lots of expansion, and the opening of not just one, but two new locations.  Keats Southwest and Keats Coastal Stamping serve not only as indicators of our expanding business, but also as brick-and-mortar monuments to our dedication to exceptional service.  Our ISO 9001:2008 and 16949:2009 certifications also speak to our pursuit and achievement of the highest quality standards. 

As innovators and the best business minds find new ways to build better businesses, you can be sure Keats will be here implementing and adapting best practices to the needs and benefits of our clients.  Within custom manufacturing, you’ll not find better customer service than with Keats.

                                                                                                                               

Keats’ Commitment to Safety

June is National Safety Month, and we at Keats heartily approve of the push for awareness and implementation of robust safety procedures in the workplace.  Part of what constitutes a job well done for us is a job that minimizes the risk involved with the operation of custom manufacturing equipment to provide the highest levels of safety and comfort to our employees, and peace of mind to their families.  It’s a commitment of ours, which is why we are doing our part to encourage best safety practices, and have taken proactive precautionary steps in our own shop to ensure we keep our employees safe and healthy.

We maintain a high level of cleanliness and organization on our shop floors – reducing clutter is not only efficient for productivity, but we've found that maintaining clear pathways between machines and organized works paces leads to a safer work environment.  It’s been years since we've had a lost-day accident – and this is thanks in large to our commitment to the continual improvement of our safety protocols.  Another proactive measure we've taken is to meet with our floor managers to design improved lock-out/tag-out procedures on our machines, and improved spill containment procedures - these conversations between management and operator are important for consistency and clarity of approach, and ensure that policies are accurate and effective for our operators.  Since our machines require specialized knowledge for operation and control, we have found that lock-out/tag-out procedures work well to ensure only those trained on particular machines can use them.  For spill containment, we not only want to provide our employees with knowledge of how to prevent these occurrences, but resources and training for what to do in the event that a spill occurs – this is why we insist on having our safety training in-house, so that we can be sure each employee is given job-specific instruction for maximum safety in every situation.

These are some of many ways in which we at Keats have chosen to promote the safety of our employees.  We hope you’ll join with us in doing the same, and pursue policies and procedures that work for your company to prevent injury, protect employees, and improve lives.

Getting Involved with Education and the Environment

In February, we blogged about our internship program, and we noted that, increasingly, schools just aren’t spending enough time providing students with the critical skills they need in math and science to prepare them for real-world jobs in areas such as advanced manufacturing.

So we would like to take this opportunity to promote an initiative that is working to remedy this problem. A group called the Joint Policy Board for Mathematics held educational activities throughout the United States in April to boost awareness among young people of the importance of science, technology, engineering and mathematics (or STEM).

These efforts (in the form of special lectures, events, contests, and so forth in schools) focused on the “Mathematics of Sustainability” in order to “spotlight the role of mathematics in helping us balance human needs against the world’s resources while operating within the constraints of nature, while seeking creative solutions for a sustainable way of life.” It’s quite a mouthful, but we think it translates into reaching out to the next generation of Americans to emphasize how important it is to study hard not just for themselves but also for their communities -- and even their world.

For example, in our own shop, we recently held an eight-week basic metalworking skills class in partnership with the Jane Addams Resource Corp. (JARC) for our newer employees. We taught math as it applies to manufacturing (introduction to statistical control, etc.). We have a joint partnership with JARC, and their instructors come out to our facility whenever we have enough new employees to run through the program (we had 12 this time).

Math Awareness Month is a worthy project, and we encourage our customers and friends to support it if they can -- even if you just tweet about it. It’s something we all have a vested interest in.

Frankly, we think every month should be devoted to improving the skills of our present and future employees. 

Closing the Skills Gap with Keats

The news has been filled with stories about a “skills gap” in the manufacturing sector. While experts disagree on the severity of the current problem, they all agree that if not mitigated it will become a very real and very big problem by the end of the decade. One study even puts the number at a deficit of 875,000 highly skilled workers in 10 years.

At Keats, we have always been concerned with finding the next generation of skilled workers. We feel that one part of the answer lies in a strong and paid internship program. In fact, we recently hired five new employees from our latest internship group. Historically, manufacturers have recruited through colleges, high schools and vocational schools. While there was a time when this might have worked, it just doesn’t get the job done anymore. Thanks to cut backs in actual hands-on manufacturing training in today’s schools, kids just aren’t graduating with a high enough level of skills or in many cases, none at all. Our internship program allows us to not only see who can develop the best manufacturing skills, it also lets us understand who will be the best as a worker, and a team member. Unlike blindly hiring based strictly on qualifications, we get a detailed look at our interns’ work habits, motivation level, and dedication to learning.

Thanks to these tangible benefits, the internship program has been a smashing success. A recent graduation ceremony for the statewide internship program, which has supplied interns to Keats, not only produced some promising new employees but also featured a speech by Illinois’ Senator Dick Durbin praising our efforts.

The skills gap problem is not going away on its own. Companies, schools, and governments need to focus on finding and creating solutions as soon as possible. We hope that our successful internship program will inspire others to follow us in building a strong future for American manufacturing. 

Quality Assurance in Quality Audits

Just promising a potential customer quality doesn’t always get the job done. Occasionally we have potential clients who audit our facility in advance of committing to Keats. While this kind of test might be worrisome for our competitors, we welcome them without reservation. Our secret? Something we like to call our “mature quality system”. At the heart of this unique quality system is a mature staff that has a long and prestigious record of accomplishment, including a quality manager that has been with Keats for 12 years.

Since we have always believed that quality people make quality products, we’ve never been intimidated by outside quality audits. We keep our work environment clean and welcoming, and our technology and equipment up-to-date. A dirty shop floor is more than just an eyesore, it is a sign that you don’t really care about quality, your employees, or your customers.  That is why you can walk into any Keats facility and immediately see that we are serious about cleanliness and quality.

If you choose to work with Keats, we want you to be completely satisfied. We stand behind our people, our products, and our facilities 100%. If you demand the highest level of quality for your custom metal stampings and wire forms, Keats is the right place to come. You can even come by and kick the tires! We don’t mind.

DIY Metal Stamping

Recently we have noticed an exciting and interesting new trend: the idea of Do-It-Yourself (DIY) home metal stamping. Aimed mostly at jewelry makers and artists, companies are selling kits that allow people to design and manufacture small metal stampings all in the comfort of their own homes. Before the Industrial Revolution DIY was the only way to do metal stamping, but since then most people have relied on companies like Keats to handle the intricacies of metal stamping.

For us the idea of DIY metal stamping is good thing, because it introduces and familiarizes people with the core of our business. Of course, if you can make a nice piece of jewelry at home, just imagine what the experts at Keats can do for you. Our precision, industry leading four-slide, deep drawn stamping, and progressive die stamping capabilities, are all perfectly suited for all your production-quality jewelry manufacturing needs. With outstanding design flexibility and the ability to maximize the use of each piece of pre-patterned and coated metal sheet metal, we turn your ideas into high-quality products. Our methods are fast, reliable, and multi-functional and we have a great selection of secondary services.

If you are looking to turn your small jewelry making business into something more, then you might want to consider entrusting your metal stamping to Keats. We treat all of our customers like family, so you know your dreams and art will be in caring and expert hands.