There are three stages in the sheet metal fabrication process; prototype, batch processing, and mass production. In this brief but informative guide we give you a quick overview of how each process takes place.

Prototype

A prototype is the first step and involves making a mock-up of the final part. A prototype may show up things that need to be changed, such as dimensions or finish. The prototype stage is hugely important as it can prevent losses from batch producing parts that are not quite to your needs. Prototypes can also be used to demonstrate at trade shows or to show investors. Companies such as //dkmsheetmetal.co.uk/ provide prototypes as a key part of their design and development service.

Batch Processing

At this stage of the part in question is produced at a low volume, anywhere from 25 to a thousand pieces. This is an especially necessary step for parts or products that are new and need time to grow in the market. The batch production stage can also respond to changes to the prototype.

Mass Production

Mass production is the stage when a client is ready to sell the part on a large scale. This will usually only be requested once the batch process has proven successful and when there is some sort of guaranteed contract for large scale sales.

All new products should start at the prototype stage to reduce risk and get the final product just right. Mass production should only be entered when you know you have the buyers for your part.

Most systems continue to operate year after year without incident until the point is reached where patching problems to keep the system operating is no longer cost effective and it is time to replace the system a number of times.

Dead Zones That Never Improve

If staff are missing calls in specific parts of your building and repositioning the receiver in different locations does not make a difference then the range of your system has probably deteriorated over time. Radio frequency signals have less consistency with older radio hardware and even with the best of setup there is a point at which no further adjustments can be made.

Missed Calls Are Becoming Routine

The occasional missed call is never going to be perfect but when it becomes a regular occurrence the problem has become apparent. A system that fails to function at its primary function is useless. In addition to normal operation, staff may start to work around the problem by shouting down corridors or using their personal mobiles.

Parts Are Discontinued or Hard to Source

When a manufacturer stops supporting a product line for which there are no more new units in warranty the chances of finding replacement receivers, transmitters, etc. and adequate stocks of batteries in due course also rapidly diminish. As a general rule, the costs of maintaining equipment in a workplace to a satisfactory level of reliability must be balanced against the risks of running an unsupported product but if in doubt it is best to err on the side of caution.

Staff Are Working Around It

Watch how your team behaves during a busy shift. If your staff have stopped using a particular function on a system no longer, then they are working around the problem. This is a much clearer indicator that there is a problem than a fault report.

It Won’t Pair With Newer Hardware

Because many older systems are not able to be paired with newer call button technology, it is likely that you will need a wireless call system that works with current hardware. If you are looking for a Pager System, see https://www.dinggly.com/us/.

If two or three of the above indicators apply to your specific situation then it is time to start looking for a replacement.