Every customer hopes that the sheet metal fabrication shop they work with can save them time and costs. A truly professional sheet metal fabricator not only delivers high-quality finished products, but can also meet the customer's expectations while maintaining quality standards and not cutting corners.
But specifically, how does a professional sheet metal fabrication shop accomplish this difficult task? Let me tell you!
Table of Contents
- 1Putting quality above all defines the professional approach
- 2Want to Save Time and Costs? Confirm These 4 Things First
- 2.1Precision Level of the Product (Tolerance Requirements)
- 2.2Product Quantity
- 2.3Material Used for the Product
- 2.4Repeat Order or New Product
- 3Proactive Quality Checkpoints to Avoid Costly Mistakes
- 3.1Initial Process Planning
- 3.2Partnering with Quality Component Suppliers
- 3.3Pre-Production Meeting to Finalize Processes and Drawings
- 3.4Precision Metal Manufacturing Ensured by Expert Technicians' First-Time Sampling
- 3.5Multi-Stage Quality Inspections to Ensure Precision and Zero Defects
- 3.6New Product Introduction (NPI) Process Implementation
Putting quality above all defines the professional approach
If there is a smarter method available, don't use the clumsy method. This is the original intention behind saving time and costs for any product – to cut costs and save time. However, this absolutely does not mean "cutting corners."
A professional sheet metal fabricator will put "quality" first. Even if there are methods that save more time or money, if the quality gap from expectations is too large, a professional fabricator should proactively inform the customer of the risks. They will not resort to unscrupulous means just to save time or money.
Want to Save Time and Costs? Confirm These 4 Things First
Sheet metal fabrication can be used to produce a wide variety of products. Therefore, to save time and costs, the first thing to look at is "what type of product needs to be made"?
The required materials, manufacturing processes, and time are all different for products like machine tools, medical devices, or semiconductor manufacturing equipment products. Generally, the more advanced the product, the harder it is to save time and costs, because there are more critical requirements that must be monitored.
However, a professional sheet metal fabrication shop can still determine the fastest and most cost-effective approach by considering the following:
- Precision Level of the Product (Tolerance Requirements)
- Product Quantity
- Material Used for the Product
- Repeat Order or New Product
Precision Level of the Product (Tolerance Requirements)
The more precise a product is, the more details need to be monitored, because the production team must pay attention to the "absolute tolerances" and "geometric tolerances" (parallelism, angles, positioning, etc.) noted on the drawings. More time is also required for testing methods, possibly even developing dedicated jigs/molds to assist fabrication. Significant effort must then go into inspecting quality, making it harder to save time and costs.
So if there are no special requirements, the sheet metal shop can be requested to manufacture using the most general specifications and pricing. At BLIKSEN, our general tolerance is ISO 2768 mH grade, which we publicly share as a reference.
In addition to manual manufacturing, BLIKSEN also utilizes robotic arms capable of meeting customers' sheet metal tolerance requirements. Pictured is an automated press brake machine in BLIKSEN's facility.
Product Quantity
Nowadays, professional sheet metal fabricators usually have machinery to assist production. So if the product quantity is high and the processes are not too precise, it is possible to achieve fast, high-quality, and inexpensive results, because current machinery allows for automated production.
Take our welding robotic arms at BLIKSEN for example. Once programmed with the right parameters, we can hand over less complex products to the robots. They'll work tirelessly without quality issues from fatigue that a human welder faces after long hours. The staff supporting the robots don't need deep technical expertise either. Just having one operator to handle loading and unloading allows the robotic arms to keep running continuously, delivering consistently high-quality output.
If the sheet metal shop invests in robotic arms for material handling, they can achieve completely unmanned production running 24 hours a day. In this case, their capacity and pricing can be more competitive than semi-automated facilities.
Conversely, if the quantity is low or even just a single unit, manual production is recommended, because while robotic arms produce quickly, the upfront programming and adjustments are very time-consuming. Setting up for a new product and positioning the arm takes at least 4 hours.
According to Fei-Wen Yang, Production Manager at BLIKSEN, an order quantity over 300 units is considered high-volume production for our facility. Therefore, customers can preliminarily evaluate based on their target quantity whether their job is better suited for our automated or manual manufacturing approach. This allows us to deliver the most competitive unit pricing for their specific order size.
In other words, if you commission BLIKSEN to produce over 300 units of a product, we will likely utilize automated equipment to save you time and costs.
However, keep in mind that each sheet metal shop has different equipment, processes and capacity allocations. So if not commissioning BLIKSEN specifically, you should inquire about that vendor's quantity definitions.
Material Used for the Product
Just like fabrics, in addition to natural metals there are also many composite alloys, with quite a diverse range of options. Each material has its own cost and properties, so the choice impacts expenses.
For example, 6061 aluminum has high hardness and wear resistance properties. But if bending is required, it needs heat treatment first to avoid cracking. If hardness and wear resistance are not required for the part, 5052 aluminum can substitute at lower cost by skipping the heat treatment.
Moreover, some products require special materials or additional processing due to harsh operating environments, further increasing costs. So environmental factors must be considered in advance and communicated early to the sheet metal shop to receive optimal solutions.
Material sourcing location is another factor - not every material is available domestically in Taiwan. If unavailable locally, it must be imported from overseas first before fabrication in Taiwan, requiring evaluation of shipping costs.
At BLIKSEN, after ordering materials for a customer, incoming materials go through inspection to reject substandard materials before entering production with premium quality stock.
BLIKSEN commonly works with materials like carbon steel, stainless steel, and aluminum alloys, with sheet thicknesses ranging from 0.5mm to 20mm. The image shows typical sheet metal stock of various thicknesses.
Repeat Order or New Product
In sheet metal fabrication, aside from material and processing fees, another major cost is drafting/design. At BLIKSEN, each new drawing takes 4-8 hours, and for very complex/detailed products, even more time and cost.
However, if it is a repeat order - meaning the same sheet metal shop produced this product previously - then the drafting process can be skipped and it goes straight into fabrication for faster turnaround.
Proactive Quality Checkpoints to Avoid Costly Mistakes
A professional sheet metal fabricator not only understands the manufacturing processes, but also knows at which stages to implement quality checkpoints along the way. This prevents one misstep from compounding into a failed end product after wasted effort. At BLIKSEN, once a quote is approved, we typically go through the following process with built-in quality checks at each phase. This allows us to deliver accurate, defect-free products on time.
In general, BLIKSEN ensures quality control over the following items for our customers:
- Initial Process Planning
- Partnering with Quality Component Suppliers
- Pre-Production Meeting to Finalize Processes and Drawings
- Precision Metal Manufacturing Ensured by Expert Technicians' First-Time Sampling
- Multi-Stage Quality Inspections to Ensure Precision and Zero Defects
- New Product Introduction (NPI) Process Implementation
Initial Process Planning
Unless it is an extremely advanced product, a professional sheet metal fabricator can usually evaluate the overall manufacturing process just from reviewing the drawings and quantities. This initial process planning allows them to assess:
- Do we have the required material in stock currently? If not, how much time and cost for new material procurement?
- What components/parts are needed for this product?
- Can all the operations be completed in-house?
- If outsourcing is required, which processes need to be subcontracted? Are there alternative solutions or materials?
- Which processes can potentially be eliminated or optimized?
- Does this require new tooling/molds?
After this preliminary process evaluation, the customer quote will be provided based on the planned manufacturing route. A professional sheet metal fabrication shop may even proactively identify potential production issues during the quoting and drawing review stage. These factors could all impact timing and costs, so they must be communicated upfront.
Partnering with Quality Component Suppliers
A professional sheet metal fabricator partners with component suppliers who share the same values and integrity. The experienced procurement and engineering staff deeply understand manufacturing processes and hardware components. This allows them to identify which suppliers are reputable partners who quote fairly without inflated pricing.
By vetting suppliers upfront during the quoting stage, they safeguard the customer's interests, creating a win-win-win situation!
Pre-Production Meeting to Finalize Processes and Drawings
Although the engineering department conducts an initial process evaluation during quoting, many details still need to be further coordinated across departments before the project kicks off.
Therefore, BLIKSEN always holds a "Pre-Production Meeting" where the engineering team invites representatives from sales, materials, manufacturing, quality, and other relevant departments. Together they finalize the production approach for each process step. For overseas customers, packaging and shipping methods are also discussed.
At this meeting, each department provides their professional insights and recommendations. The initially planned processes are likely to be modified based on input from the floor-level experts into detailed, shop-floor manufacturing drawings.
For example, one past project had the customer's drawings specifying three metal plates for the final product assembly. However, after reviewing the drawings, our engineering team determined it could be produced using only two plates without compromising quality or performance - while saving time, material, and costs. We proposed this alternative approach to the customer and obtained their approval to proceed with the two-plate design.
That said, any changes to materials, components, or hardware must be approved by the customer. If they do not accept our recommendations, we will still manufacture precisely according to their drawings, as they understand their product requirements best.
Precision Metal Manufacturing Ensured by Expert Technicians' First-Time Sampling
For common or frequently repeated products, professional sheet metal fabricators have extensive experience and low error rates. However, many of BLIKSEN's customers come from high-end machinery industries, often presenting designs we've never encountered before.
To avoid wasting entire production batches, veteran technicians take on the critical responsibility of producing the initial sample units themselves. They document key areas requiring special attention during fabrication to coach the rest of the team.
For example, when Assistant Welding Supervisor Jia-Heng Dai receives a new product like a large machine frame, he will personally weld the entire first unit from start to finish as the sample build.
During this process, he establishes the production workflow, creates standardized work instructions, provides hands-on training for the manufacturing approach, and highlights specific operational areas needing extra care - preventing material and time wastage.
The welding sequence is particularly crucial, as deviations could lead to failures meeting tolerances, part deformation, or inability to support intended loads - all critical defects.
Welding technicians follow technical documents and use fixtures or Welding Process Specifications (WPS) for new products during welding operations. The image shows a welding technician at work in BLIKSEN's facility.
Multi-Stage Quality Inspections to Ensure Precision and Zero Defects
At a professional sheet metal fabricator, every technician on the floor has the mindset, skills and responsibility to uphold quality standards.
For example, at BLIKSEN's laser, bending, and welding departments, each operator performs a "self-inspection" after completing their process step by using measurement tools or gauges to verify dimensions are within tolerance.
We also have a "patrol inspection" system where quality personnel re-inspect completed workpieces before they proceed to the next operation. This prevents passing on issues that could obstruct downstream colleagues and cause rework, missed deadlines, or quality defects.
Additionally, BLIKSEN's production supervisors have received basic quality training. They conduct daily floor walks to monitor progress and immediately alert relevant departments if any major quality issues are identified for correction.
If no problems are found in the preceding steps, the parts finally go to the quality department for a Final Quality Control (FQC) inspection and Outgoing Quality Control (OQC) before shipping.
For semiconductor industry products, we add an extra "First Article Inspection" (FAI) during the initial sample run to validate processes before full production.
The image shows a quality inspector at BLIKSEN using a 3D measuring instrument to inspect product quality.
New Product Introduction (NPI) Process Implementation
NPI (New Product Introduction) is commonly used in technology industries, but not always by sheet metal fabricators. However, many of BLIKSEN's customers are in advanced sectors like semiconductors, medical devices, and energy storage where even minor defects can have cascading consequences.
While we have a sample production habit, the yield rate between making one piece and a thousand cannot be the same. With only a single sample, some details may be overlooked. Even with 99.9% yield, that remaining 0.1% could severely impact products in these critical industries.
Therefore, BLIKSEN has implemented a formal NPI process with particular emphasis on Production Verification Testing (PVT). We carefully select the most suitable equipment and personnel to produce with maximum efficiency, minimizing time and material waste.
Beyond that, upon receiving drawings, we generate a Bill of Materials (BOM) and manufacturing work instructions based on customer requirements and notes. This documentation formalizes all processes so different operators involved in full production can achieve sample-equivalent quality.
Despite these stringent checkpoints, a professional sheet metal fabricator thinks from the customer's perspective from initial inquiry to deliver high-quality, efficient products and services within reasonable expectations.
If your organization is seeking a sheet metal fabrication partner, consider the above details to identify a suitable match. While every fab shop specializes in certain products, if yours demands precision and aligns with BLIKSEN's philosophy, we welcome you to submit an online RFQ. We will promptly evaluate your needs and discuss the optimal solutions.
Source: Based on accounts from Fei-Wen Yang, Design and Production Manager at BLIKSEN. Compiled by Yu-Ling Chiu.
Concept and Topic Selection | Pini Lee, YuHan Chen, YuLing Chiu
Interviews and Writing | YuLing Chiu
Review and Proofreading | FeiWen Yang, Pini Lee