How a DFW Metal Fab Shop increased throughput by 38% with no added labor.

Every job on your board this month will ship on time. You'll make sure of it — that's the job. It's also where the story gets expensive.

Because you know what it took:

• the Saturday shift

• the overtime

• the temp hire

• the next job that is now behind (and will cause another saturday shift)

Top-performers are completing 9.3% more and they aren’t relying on heroics. They are top performers because they are always looking for the next win in their operation.

Stalled jobs don't always show up the same way. In your shop, it looks like:

• Excessive grinding during post weld clean up

• Rework tickets due to inconsistent weld quality

• Working Saturday overtime shifts

• Temp laborers hired and trained just to keep pace

• Bids you didn't take, because you already knew you couldn't staff them.

Maybe it's one of these. Maybe it's all of them. The root cause is the same.

Your welding process is holding you back.

That's where stalled throughput hides. Where every cost is coming from. It used to be “just the way it was” – but that is no longer the case.

Here's the real issue with MIG and TIG, there are only three ways to increase production.

1. Work more hours.

2. Hire more people.

3. Sub out more work.

That's the whole menu…

Every option on that list costs you money, time, or control. Usually all three.

What if you had another option?

When MIG and TIG were introduced, most shops held onto Stick (SMAW) welding, even as the numbers showed a 2x or greater production jump.

Familiarity felt safer. Until businesses had no choice they either adopted or were no longer competitive bidding for jobs, production went to MIG for speed or TIG for control.

Since then? Nothing. Equipment's been refined, not reinvented. Buying a welder is still two questions: what's it cost, what brand is it.

Where did metal fab's leap forward go?

We still think MIG and TIG have their space.

Laser welding used to mean aerospace budgets and clean rooms. Now it's sized and priced for every shop.

• Hand-Held for all applications

• All material capable

• Affordably Priced

In Traditional welding, the weld is only as good as the person holding the torch that day. Laser welding eliminates that.

The process is operator-set. The weld is equipment-produced.

Your operator dials in the parameters and the machine controls the weave and speed. Same weld every time, weld after weld, shift after shift. All the operator has to do is hold it in the weld joint.

What that does to your output:

• 1.5-3x faster welding than MIG

• 4-6x faster welding than TIG

• 80% less grinding

• 30%+ increase in overall production throughput.

• 74% reduction in consumables per inch of weld

• New operators are productive in days, not months or years.

This equates to ~$16,000 per machine savings per year over traditional welding systems for an averaged sized metal fab shop. (Assuming $30/hr & 30 hours per week of welding)

Customers of ours who have bought are seeing these results:

A light metal fab shop in Dallas - Fort Worth was running the same playbook you are — Saturday shifts, temp hires, weekly welding training, a good welder ready to walk. They didn't change their team. They changed their welding system.

Inside a few months:

• throughput up 38%

• welding rework gone

• new hires production welding in days

• jobs back on the board they used to pass on

They just stopped accepting something the industry has been calling “Normal”.

That's not a different shop's story.

That’s your tomorrow.

PEBCOR Laser Solutions LLC dba PLS

Discover the efficiency of laser welding today and unlock its potential to revolutionize your manufacturing processes. With its precision and speed, laser welding offers unparalleled advantages that can enhance your productivity and reduce costs.

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