We’re producing IPE100 European I-beams for a project in Colombia. This shot is our workshop cooling bed right after hot rolling. The profiles sit here to slowly cool, then go through straightening, dimension checks, surface inspection, marking and bundling.
We make stainless food processing equipment, and our one drafter is three months behind. Most of the backlog is fixtures, jigs, and small revisions. I'm stuck between hiring a second drafter and sending some work out.
My worry is an outside drafter won't know which dimensions need inspection. They might also miss a tolerance stack that our guys would catch. CAD/CAM Services is one US-based option I'm looking at for overflow. They quote by project though. That may not fit if the work never slows down.
How do you decide what stays in-house and what goes out?
For fab/equipment engineers: When a 15–20 year old Ebara/TEL/SCREEN/etc. tool goes down and your internal team can’t figure it out, who do you actually call?
OEM? Former employee? Contractor? Someone else?
And have you ever actually paid an independent engineer to solve something like this??
This is going to be a LONG explanation, but it is relevant for you to understand my situation. Each paragraph is titled for easier mental navigation back and forth.
My work experience so far:
I'm currently a process engineer for a steel foundry (5 years with the company, first 2 in a rotational program straight out of college, last 3 years in the foundry) working a hybrid (shop floor/desk work) role. My degree is in metals manufacturing, with a focus on foundry processes. You can imagine why I was drawn to this role. I got into foundry work because I really have a passion for melt practices/melting equipment and process improvement. Through my tasks and projects I've really increased my knowledge in metallurgy, refractories, melting/refining equipment (induction, electric arc, AOD), process auditing/investigation/control, the DMAIC process for green belt projects (working as a team member on several and also one of my own), writing procedures, and training new hires.
Why I'm asking for advice:
As much fun as this might sound to some people, all of this experience has come with the burden of terrible leadership. I think a lot of people can say what I'm about to say. When the chips are down, I put in the extra time and effort to make sure my team succeeds because I care about being a team player that uses my abilities to help those around me. But poor leadership has killed my motivation. There are times when I have been brutally called out for things that were not my fault (where my innocence was proven but I received no apologies afterwards), I have taken quite a bit of time to construct procedures for jobs with no available training that are performed by single individuals that have left or are planning to leave soon (often a role that nobody in leadership pays attention to but also one that they want training completed for immediately when they find out how necessary it is), my time has been disrespected and abused to train new hires (pulling me away from what I was already told was priority but now I have to make sure I get those priorities done while also making sure the new guys are on track in their training schedule) because I was told the supervisors don't have the band width to train their own people, projects are discussed in meetings that no one thought to make me a part of and then I get sent a short email or told on a fly by, as someone is going out the door, that I have a new project to work on, and if anything causes inconvenience to a team that I'm apart of, I'm the one who gets asked to change my schedule or do extra work so no one else is affected. I consider myself to be a nice person, which is part of why I think they see fit to abuse me so much. They know I'll eventually regain my positive attitude vs the other people that just complain or find a way to pawn off the work.
Why I've worked in these conditions so long:
Keep in mind, this is the leadership team that makes it hard to continue working here. It's completely different with the rest of the crew. The other engineers and the guys on the shop floor are awesome. We all get along great. We fist bump every time we pass each other. The guys on the shop floor give me a lot of praise for the quality of work I provide because they know I care about making this foundry successful despite how much we all have to deal with. They make it worth coming back every day. But leadership's failure to make sound decisions and treat people with respect, combined with continuing to hear how desperately the shop floor guys (and several of the engineers) want to find somewhere better due to production being held on a pedestal above quality, is making me want to leave with them, and leave for good. The shop floor guys have even told me that they enjoy the workplace more when I have my cheerful attitude (that's just me by nature), but want me to find a place where I don't have to fight everyday to keep that same attitude.
The reality I'm aware of:
As much as I want to continue working in manufacturing, I fear that I'll only find the same situation. Ranging from slightly better to definitely worse. Several good friends of mine are in the same situation with their manufacturing companies and are also on the verge of leaving but have no idea what role to take on next or with what industry.
My outlook on next job flexibility:
I'm not tied down to foundry work as a day job anymore. I used to think I'd be in this industry forever. But, it's become my favorite hobby at home so I would satisfy that passion/itch in other ways. I was thinking about it the other day and said to myself "I think I would enjoy foundry work at home even more if I didn't work in one for my day job". Basically because reading about all the things I want to build and experiment with is great until it reminds me of how poorly we execute those exact processes at work. I could definitely work in another department or in another industry, so long as the job/environment doesn't make me force myself to forget about work just so I can enjoy my evening each night. I understand that sometimes the workplace can get hectic, but when people try to tell you that things will get better and they've only become worse over time, it takes all the wind out of that sail of hope. Especially when you hear nothing but corporate jargon from the executive team and keep being told "we need to do better as a whole" at the company meetings. Really? Better as a whole? Thanks for the motivation. I've heard that I don't know how many quarterly meetings in a row. Now you really make me want to stay.
Not just a fresh engineer anymore:
Personally, I don't like how this entire company has been managed. I know 5 years with a company isn't a lot, but it's been long enough for me to grow my skills and independence as an engineer. Taking on projects for myself versus waiting for my boss to fill my plate has been very rewarding and makes me feel more in control. I feel as though I have even more to offer to whatever next job I take if the workplace is rewarding and respectful. Quick note for those still reading, I don't have any interest in leadership roles. I like working with materials, systems/practices, and equipment. Managing people and dealing with constant company politics has never interested me. I don't really care about hitting a certain level and not moving further in a company. If this leadership team, company, and environment were better I'd continue working this position for many years.
Design experience with willingness to learn more:
If it helps anyone giving advice, I love using OnShape modeling software in my spare time. I would say my skill level is "intermediate" on the scale of "begginer-intermediate-advanced" when it comes to 3D modeling. I used Solidworks in school and have used OnShape for the last few years. I enjoy building individual parts (using different tools and methods to better understand design theory and future change capability) and assembling them as a final product. Part of my "foundry at home" hobby involves designing furnaces that I want to build for ferrous and non-ferrous melting.
Thank you:
Lastly. Thank you for taking the time to consider my situation and contribute any help. I look forward to your advice.
I'm looking to enter electrical-electronics something manufacturing, such a vast domain , but i know that starting at a specific niche will be much more efficient than manufacturing something that is already being mass manufactured , every path I see like cable manufacturing, solar control panels etc are all completely crowded , companies are there for 50+ years with millions of capital and I'm here with close to only 100k after loans . Why would they even choose me over them ? I would like to have a Convo with a few people who are familiar in this domain.
You see, the production manager, also very proficient in the field of Quality, has made the next process reliant on the previous process, so that the whole thing becomes a fault-free product at the end.
But the thing is... we are currently using about 40% of our production capacity, and next month, we are going 100%... and here's where I'm worrying.
If in 300 pieces per day, there are like 10 reworks done by the next station, that would mean about 40 reworks at 100%... not to mention the energy of the workforce dropping as the time passes by (we currently shut down at 4PM, but we are planning to increase the working hours to 7PM for full scale manufacturing) which would lead to more faults, as I have studied.
Here is where I'm worried about: what if the workers miss these reworks and it show up in the final product? I've raised this concern to the Production manager, he said that in about 5 years of working, we had zero issues with the customers. I've already checked the records, and it's correct.
Am I overthinking this? If all is well, what should I do?
I have Quality Control and Laboratory under my domain. Just yesterday, we got a grade level up, complying with IATF16949.
Looking to have a mentor or consultant with an expert manufacturer that has or have had 30+ employees or defense contract? I have a 3d printing company