r/manufacturing

When a same manufacturing concern gets discussed multiple times without fully becoming clearer, but because output still exists, noboday treats it like a real blocker yet. From the outside, the project still appears active and progressing. Internally, uncertainty keeps accumulating in small ways.

IMO a lot of production problems don't come from catastrophic failures. They come from organizations slowly adapting to unresolved constraints until the drift itself becomes invisible.

Hello Everyone!

I am a Production Scheduler, by trade, and I have to try to figure out how to build a measurable schedule for a work center that is managed entirely by manual, daily prioritization.

This awful shared resource is Inspection. We have a large high mix, low volume machine shop, with complex routings that bounce all over the floor, but which always route through inspection, after each machining operation.

We schedule machines by lot, but for some reason, we schedule Inspection piece by piece, as it shows up to the department (and there is ALOT of material churn and demand, in this department). Whereas we are running machines efficiently in lots, we will dink and dunk through inspections, one or two or three units at a time. Available work changes every day, priority changes every day.

How do I create a measurable schedule for this type of work center? Or is a traditional schedule not the right approach, for a work center that functions like this?

Thanks in advance!

https://preview.redd.it/5pd9duowl62h1.png?width=794&format=png&auto=webp&s=688ba4c802dc8dff3d9b2d10f2d6bd00113b9b6b

coming back on reddit for some help and/or direction. i have a STEP file of a shelf i want to manufacture that is about 30 inches long x 23 inches tall. i put this into xometry (a custom manufacturing site) to have it 3d printed with vapor smoothing finish because i want to replicate ABS material for the prototype, however the quote for this was around 4k, which i did not expect. is this really the cost to produce a single prototype for this or am i doing this wrong? ideally, i want to find someone who can make the parts of this (based off my step file) and vapor smooth them and just send me the parts and i can build it myself if that is cheaper. does anyone know where i could go and how much this should cost? i really appreciate the help! i don't know a lot about manufacturing if you couldn't tell ;P I attached a reference photo of what the shelf will look like.

In theory, manufacturing inventory should be precise - raw materials in, WIP tracked, finished goods out.

But in practice, I keep hearing about mismatches coming from small breakdowns: scanning gaps, timing delays, or returns not being recorded cleanly.

From your experience, what’s the real root cause - people/process, or system limitations?

https://preview.redd.it/jk14pke36b1h1.png?width=1684&format=png&auto=webp&s=08a92e3d8cd4e2ae57df5876532464dcf15cb1eb

We'll be here next Thursday 21st May, 3–5pm BST to answer your questions, with a focus on industrial and embedded use of Raspberry Pi.

Between the three of us we cover the full stack, so bring whatever you've got; board-level hardware questions, software and OS questions, the Compute Modules, RP2040/RP2350, real-time performance, interfacing with industrial protocols, or broader questions.

Post your questions now and we'll work through as many as we can on the day.

See you on the 21st.

— Eben, James & Gordon

Hi everyone, I’m a 55-year-old Industrial Engineer (BSIE) with an LSSBB and PMP, currently working at a major EV manufacturer’s primary facility in Texas. I’ve been here about 2.5 years and have worked across several areas including Body in White, End of Line, and most recently dimensional engineering/CMM.

My earlier background was heavily IT-focused, so I haven’t formally worked under an “Industrial Engineer” title before, even though process improvement and continuous improvement have always been my strongest skills. I’m in a technician role and actively trying to position myself for a stronger long-term role - thinking Manufacturing Engineer, Process Engineer, or finally in a true IE role.

One thing I’ve enjoyed about this environment is exposure to modern manufacturing technology. Lots of cool stuff. I’ve worked around Fanuc robots, Siemens HMIs, and automation systems, and in my current role I’m diving into GD&T, Python, Zeiss, PolyWorks, and dimensional analysis. I’m hoping this combination of manufacturing, quality, data analysis, automation, and IT experience can help bridge into where the industry seems to be heading with AI and smart manufacturing.

Due to some organizational and leadership changes, I’m starting to explore other opportunities. I’d appreciate advice from engineers, manufacturing professionals, or others who’ve transitioned from IT into manufacturing engineering, especially regarding the current job market, skill gaps worth addressing, or where someone with my background might fit best.

Thanks in advance.

edit: added details

Hi everyone!

How many people still use paper log sheets on production and manufacturing sites?

Does it looks like an area they can be improved or it is just my experience that is not very relevant to the average?

Automation discussions often make it sound like robotics adoption is happening everywhere equally.

But it still feels heavily industry-dependent. Automotive seems relatively mature.

Meanwhile, several mid-scale manufacturing environments still appear hesitant because integration and ROI timelines remain unclear.

Curious whether cost is still the primary concern or if implementation complexity is the bigger issue now.

I work in procurement for an automotive manufacturing company, mostly handling component suppliers and production materials, and honestly the past few months have made me question whether "stable supply" actually exists anymore. We've had suppliers increase pricing after samples and validation were already approved. Another supplier spent weeks during onboarding talking about how reliable their lead times were, then immediately started delaying shipments once production volumes increased. And in automotive manufacturing, one delayed component doesn't just create inconvenience. It can throw off downstream schedules across multiple teams. Then we had another supplier issue where the material technically passed specifications, but actual batch consistency during production was terrible. Same supplier

same material code. Completely different appearance and processing behavior depending on the batch. Quality was frustrated. Production was frustrated. And procurement somehow became the department expected to explain everything to everyone. But the worst situation recently involved a supplier we'd already worked with for quite a long time. Active automotive project. Aroduction schedules already locked internally. And suddenly the supplier started slowly disappearing. Slower replies every day while continuing to say things like "everything is moving forward" and "shipment should be ready soon". Which honestly feels worse than simply admitting there's a problem. Because internally everyone keeps asking procurement for updates while procurement is also waiting for answers.

Meanwhile management keeps asking: "why wasn't this risk identified earlier?!" As if suppliers openly announce when they're about to become unreliable. Honestly procurement in automotive manufacturing sometimes feels less like purchasing and more like full-time crisis management. The frustrating part is that these suppliers originally looked completely fine on paper. Competitive pricing. Acceptable samples. Good communication during onboarding. Everything looks professional until actual production pressure starts. Then suddenly all the hidden problems appear at once. Recently our team has been spending way more time documenting supplier history, recurring issues, revisions, and communication records because everyone's tired of repeating the same mistakes with different vendors. Honestly half the challenge now is simply organizing supplier information clearly enough so future projects don't walk into the exact same disaster again.

I was just curious to hear from people in manufacturing and machining. What cutting tools have given you the best results in your day-to-day work? Could be carbide tools, milling cutters, inserts, or anything else. Interested in real experiences and what you guys prefer.

Hi All - looking for a reliable shop that has cnc mills to manufacture low volume repeat orders for us.

Products are 5mm 6061 alu and are appx 7x20”

Must be in Mexico. Thank you!!

Should it be equipment upgrades, automation, or outsourcing? Also what actually gave you the best ROI in terms of cost savings or growth?

how do you go about determining your MOQs for contract manufacturing? add up R&D, changeover, setup costs, admin costs to get a program up and running, on top of any optimal batch/run size costs?

thanks!

My department has been tasked with setting up a tool control program at a mid sized manufacturing facility. Would not be surprised if our tool count was in the tens of thousands and it ranges from common screw drivers, to calibrated test equipment, to totally custom made fixtures. We are not an aerospace shop or subject to AS9100 so its really up to us how we implement. Even so, its a bit of a daunting task and we have been struggling.

Right now tools are stored everywhere. Shadow boards, shelves and cabinets, people’s desks and boxes, on random carts, you name it. They go missing all the time though and there is no accountability for maintenance or tracking. Techs spend tons of time looking for tools and often times we dont learn they are broken or worn out until there is a stop work on the floor.

Our initial plan was inventory everything, assign a location (ideally locked up), and audit regularly. There is so much stuff though we have not been able to make much headway while keeping up with our daily jobs too. Alot of the struggle has been tools moving after you have audited them and assigned a location because the program hasn’t been finalized and trained with the end users yet.

Looking for some advice on abetted way to eat this elephant. We dont have budget or space for a tool crib and attendant unfortunately.

I am looking to add more dies for new SKUs to my autoparts manufacturing business. I am in India and have been looking to get dies made for my parts. I am using plastic injection moulding machines and have been buying dies in India. I wanted to see how the experience has been for people purchasing dies from China? I manufacture automotive parts for HCV and LCVs for reference.

Hi everyone,

I'm looking for interesting industrial spaces in NYC (particularly Brooklyn but all over) to shoot — machine shops, fabrication, manufacturing, anything with interesting machinery or processes. Not looking to sell anything, just want to make some fresh work for my portfolio and would love to highlight some local businesses. I'd be happy to share the results for use on their own social media or other owned channels.

Anyone have connections or know of places that might be open to it?

I guess not strictly limited to heavy industry, would be down for anywhere with visually interesting processes.

Thanks!

^((re-posting this after chatting with and getting permission from the mods))

If you are a foreman of a sheet metal duct shop. I mean as in you are in charge of the whole shop. You get the cut sheets you enter them into the program and run the plasma, inventory, order materials, and just run the shop top to bottom. What you guys making hourly? Asking for a friend. I honestly think shop guys are undervalued personally. but I'm just trying to compare thats all. Please share if you don't mind. Thanks!