The KMK Process in Action
This is the life of a typical part in our shop.
All parts start as a quote in our MRP system. The system will manipulate the quote into several layouts as it moves through our process:
Sales Order – track quantity, price, and delivery date
Router and Work Order – through these, we track all the material, operations, and time spent on each operation.
Drawings and Technical Specifications – these can all be attached to routers and work orders so that information is readily available on the shop floor.
Packing Slips and Invoicing
We also do all our purchasing and inventory control through the MRP system.
After the quote and sales orders are complete, the part moves into Engineering. Here, we draw the part in Solidworks. We must have a drawing that clearly defines the part and contains all the information our employees need to fabricate the part. We also import this drawing into our programming software for the laser and turrets. The Engineering department will also design the shop router to contain each operation and all the required materials and hardware. The router will also make note of any specific challenges on this particular part or highlight any quality traits.
3. Laser Cutting
The design is carefully laid out on sheets of metal for maximum usage and production efficiency. Once cutting is complete, each part is inspected by someone in the Quality department to make sure everything is within tolerance.
Other components of the part are made elsewhere in the facility. In this product’s design, the lid is held on with a continuous hinge that we cut to length on a bandsaw. The operator will call for an inspection after he is satisfied he is making the part within tolerance.
After our brake setup person has the part setup and ready to pass inspection, he will have one of our inspectors verify before the operation begins.
This part is tack welded together prior to being put into the robotic welder. This is not a high-volume part so by tack welding it together, we save fixturing costs but still can take advantage of the speed and smoothness of the welds on the robotic welder. This also saves us time later on in grinding.
6. Grinding and Final Welding
We grind and sand the corners, then tack weld the hinges into place.
7. Powder Coating and Assembly
We paint the lid and body of this part separately; the hinge works appropriately. Most of our parts are assembled and packaged directly off the line, but they lend themselves to something other than that, so we assemble them offline. We install a gasket in the lid, reassemble the hinge, and install nuts and screws to hold the lid in place. The part is boxed and labeled, ready to ship to the end user once our customer receives it.
Ready to get started?
Contact KMK today to learn more about what we can offer you, or to request a quote and get started.