Machine operators, engineers, technicians, and welders are essential positions in the manufacturing job shop.  The education, experience, and skill required to do their work have been recognized among their peers on the plant floor.  Other positions are more physical in nature, but no less important to the overall success of the plant operation.  Manual parts cleaners are one such position in this category.  

In heavy industry contract manufacturing facilities like ours, this task translated to dozens of employees physically grinding slag from oxy cut or plasma cut parts. Their work required hand grinding, filing, and deburring heavy industrial parts, as well as moving, counting, and stacking them on pallets or shipping containers several times a day; every day.

While productivity in the parts cleaning department could be challenging, O’Neal Manufacturing Services’ Greensboro, NC fabrication center looked for ways to improve employee engagement, efficiency, and safety in this vital production area.  With the purchase of LISSMAC automated deslagging and edge preparation equipment, the Greensboro plant managed to accomplish all three; and has served as an example for other OMS facilities to follow. 

The Old Way

Manual parts cleaning was not just a dirty job, it was also a physical one.  Heavy steel plates were manually unloaded from the cutting tables at a steady pace and positioned on the ground for staging.  Next, they were hoisted up to a grinding table where the slag was manually removed. Each part was flipped over to repeat the process on both sides, then shifted to a holding area.  Parts were picked back up again for edge conditioning before finally being staged, packaged, and loaded up for the customer.  Aside from the repetitive fatigue, large industrial parts sometimes weighed up to 400 pounds apiece which added a substantial physical burden to the process. 

The New Way

With the addition of automated finishing equipment, parts can now be loaded directly from the plasma cutting table to the newly installed LISSMAC SBM-M D2 where they are simultaneously machined on both sides. No more part flipping is required. Dross and slag are removed in one pass resulting in a smooth and safe edge. This efficient process eliminated the exterior oxide layer, improved the surface quality of the parts, and greatly reduced the need for manual parts handling.

A second machine was installed to perform automated grinding and edge-rounding.  The LISSMAC SBM-XL G252 rounded the inside and outside contours of cut parts in a single pass, eliminated manual adjustment, and produced consistent and repeatable results.  

To further minimize overall parts handling and improve employee safety, 125 ft. of conveyor equipment was installed between the cutting lines, the deslagging machine, and the grinding device and delivered finished parts all the way to their final holding location.

“Things are totally different in our parts cleaning area now,” said Matt Moon, General Manager of OMS Greensboro.  “The group we have in there now are not trying to get out of parts cleaning. They like running the LISSMAC.  It’s been a dramatic improvement there.”

This capital investment performed wonders to alleviate the opinion that parts cleaning was one of the less desirable jobs in the plant.  Read more about O’Neal Manufacturing Services’ automated finishing equipment and its impact on production and safety in this article from The FABRICATOR. 

O’Neal Manufacturing Services (OMS) is proud to announce that we are a Certified Good Wages Initiative Indianapolis employer of choice. Overseen by EmployIndy, the Good Wages Initiative (GWI) recognizes employers who pay a sustainable wage of $18 per hour and offer health benefits to full-time employees.

“Paying good wages and providing employer-sponsored health insurance provides businesses with critical advantages in today’s labor market, from reductions in turnover to increased productivity,” says Marie Mackintosh, EmployIndy’s chief strategy officer. “Employees experience reduced financial stress and improved health outcomes while the community benefits through increased buying power and overall job growth. Good Wages Initiative partner employers set themselves apart by publicly stating their commitment to ensuring Indianapolis has a vibrant economy that is good for businesses, good for workers, and good for the community.”

With Indianapolis’ competitive job market, O’Neal Manufacturing Services recognizes the importance of supporting both current and future employees.

“We are honored to be recognized by EmployIndy. Our company has worked consistently to offer competitive wages and benefits to our employees,” remarked Federico Fraga, General Manager for OMS in Indianapolis. “Attracting and retaining great employees allows us to be successful in the markets that we serve, balancing the interests of customers, employees, and our community.”

Some have said that welding is the glue of the modern world. Though this method of joining materials through high heat and fusion has been applied for centuries, advancements in welding capabilities have transformed our lives in ways we never imagined.  Over 50% of the gross national product is affected by this critical fabrication process.  Welding-related industries manufacture goods that both sustain us and transport us.  From kitchen appliances to cars and airplanes to building structures, welded assemblies have become the driving force of our economy.

Considered essential workers, welders are needed all over the globe, and the demand for them is constant. No other technique is as widely used by manufacturers to join metals and add value to their products.  In each of our facilities across North America, O’Neal Manufacturing Services employs both manual and robotic welding methods, from lightweight subassemblies to weldments weighing more than 40,000 pounds. As we celebrate National Welding Month in April, we recognize all our employees who take part in this vital manufacturing process. 

While TIG, MIG, arc, laser, projection, resistance, spot, stud, and stick welding take place in varying degrees in each of our welding bays, the OMS team in Monterrey, Mexico has distinguished themselves by creating a welding school on-site.  The program not only supports current welders and encourages new students to learn welding techniques, but it serves as a personnel funnel to meet the ongoing demand for this essential occupation.

Launched in 2005, the OMS Monterrey welding school began as a practice arena for current welders to improve their skills. As the quality demands of customers grew more specific, the program encouraged technical growth, precision, and certifications under AWS standards. Engineer Luis Parás trained under the American Welding Society and certifies welders from within the organization to AWS D1.1 code.  This commitment to continuous improvement set new standards for employee development in Monterrey and beyond.  

In 2022, the school’s instruction was broadened to groom general welding assistants from other areas of the plant.  Safety, polishing, grinding, torch cutting, gauges, and automatic welding machine usage are covered in the program.  25 employees take part each term.  As graduates are assigned to the production lines, new apprentices are onboarded to maintain a continuous cycle of prepared welders.

Monterrey’s welding school has evolved further through a recent partnership with the National College of Professional Technical Education in Mexico (CONALEP).  Through an educational model based on competencies, students acquire relevant job skills and social values that allow them to be competitive in the workplace and pursue post-secondary studies.  As part of the curriculum, participants are assigned internships in the OMS Monterrey plant, which often leads to direct employment with the company after graduation.

“The path of teaching this profession is very meaningful and rewarding while seeing how young people are enjoying becoming welders,” said Juan Rodríguez, Human Resource Manager.  “Being a welder is being attracted by the transformation of steel.  It is a vocation of life that transforms a better world through the products we develop.” 

As the demand for infrastructure and commercial products continues to grow, the OMS team will continue to do its part to meet the ongoing needs of the modern workforce.  We celebrate National Welding Month by recognizing their efforts to educate and maintain a talented pool of welding professionals.

Original equipment manufacturers and contractors often outsource specialized fabrication services for large or complex fabrication projects. Heavy industrial fabrication jobs, in particular, require clean cuts on thick carbon and alloy steel plate. There are different fabrication methods and machinery used to make these cuts, namely plasma arc cutting and oxy fuel cutting equipment.  There are advantages of both cutting methods an OEM should consider.

When plasma cutting occurs, compressed air is combined with electricity through a funneling chamber, creating plasma gas. Intense air pressure forces the plasma gas through a nozzle creating an electrified cutting arc which is then applied to the base material.

Steel plates up to 2” thick are a good fit for plasma cutting as this method cuts quickly and precisely with a narrow kerf. Thinner steel plates can often be stacked during plasma cutting, making this an economical and efficient manufacturing process that also allows for tolerance control and repeatability.

Oxy fuel cutting, also known as flame cutting, uses oxygen combined with fuel to produce a gas torch flame. The flame jet is then directed at the base material, creating a chemical reaction required to “burn” through it and cut shapes from the steel plate. A high-precision flame cut and CNC technology are widely used in steel parts manufacturing.

Oxy fuel cutting is regularly employed to cut thick, structural, and abrasion-resistant metals such as carbon and alloy steel plate. Materials up to 12” thick can be cut using the oxy fuel method, with the high-powered oxygen jet removing slag from the kerf. The oxy burning process cuts large sections of material quickly and consistently, optimizing your workflow and reducing costs per part.

O’Neal Manufacturing Services (OMS) offers both plasma cutting and oxy fuel cutting services to produce high-quality metal components for our customers. A supplier of metal fabricated components, sub-assemblies, and weldments, our primary focus is to help original equipment manufacturers and contractors who are seeking a partner for any type of heavy plate fabrication project. 

O’Neal Manufacturing Services was recently chosen to receive a 2022 Safety Award of Merit from the Fabricators & Manufacturers Association, International (FMA). Open to all FMA company members, the FMA/CNA Annual Safety Awards recognize metal fabrication companies that adhere to excellence in safety.

Sponsored by CNA, the endorsed business insurance carrier for FMA, the Awards are designed to promote safety in the industry, and winners are selected by the FMA Safety Council. The Safety Award of Merit is given to companies posting an injury and illness incidence rate for the reporting period that is better than the published Bureau of Labor Statistics (BLS) rate by 10 percent or greater, based on their NAICS code.

“I congratulate O’Neal Manufacturing Services on winning a Safety Award of Merit,” said Edward Youdell, president and CEO of FMA. “Safety is clearly a priority for the company. They set a good example for others in the industry. FMA and CNA are proud to recognize all our safety award winners.”

To be eligible to receive recognition, companies were required to submit OSHA Form 300A, Summary of Work-Related Injuries and Illnesses, for the period Jan. 1, 2021, through Dec. 31, 2021. Firms of all sizes were eligible. Winners were selected based on North American Industry Classification System (NAICS) code categories and BLS injury and illness incidence rates. The complete list of 2022 award winners has been published on FMA’s blog at www.fmamfg.org/blog

Original equipment manufacturers (OEMs) specialize in developing quality parts and sub-assemblies for specific businesses. Their work includes design, engineering, high-volume manufacturing, and assembly of parts and components based on customer demand.

Successful OEMs manage multiple components with large numbers of identical parts and can lead to part production numbering in the thousands to tens of thousands or much, much more. Managing this kind of volume requires them to plan for the lifecycle of the part, source raw materials, and forecast the overall production process for repeatability, high quality, and long-term sustainability.

The downside of this success is the inevitable strain on the OEM supply chain to meet production schedules, which often leads them to partner with a contract manufacturing business to provide materials, fabrication, and assembly for specific components along the way.

• One example of such a partnership would involve an OEM that does not have the labor force to keep up with high-volume production. This spurs them to outsource certain steps in the fabrication process to receive parts on time. 
• The OEM may want to avoid sizeable capital equipment investments. Utilizing specialized fabrication machines from an outside partner would be preferred over purchasing costly new equipment themselves.
• As material costs rise and lead times grow, it’s important for the OEM to have a strategic procurement partner.  Contract manufacturers offer a qualified supply chain commitment to support the product life cycle.

For high-volume manufacturing to be sustainable, improvements in cost and efficiency can be significant when extended over thousands of pieces. The decision to work with a contract manufacturer allows the OEM to make the best use of their workforce, minimize capital investment, and reach their long-term production objectives.

O’Neal Manufacturing Services (OMS) is a supplier of fabricated steel components and welded assemblies. Our primary focus is to help original equipment manufacturers who are seeking a partner to manufacture parts, streamline in-house production, and produce locally at or below targeted costs. Specializing in parts that originate from medium to heavy gauge steel plate (1/8” or thicker), we have the skill, expertise, and state-of-the-art equipment to produce complex parts with tight tolerances with precision and accuracy.

Our business supports customers in a variety of equipment markets including agriculture, material handling, power generation, construction, elevators and moving stairways, forestry, industrial, oil & gas, railroad, renewable energy, and trucks & trailers. O’Neal Manufacturing Services brings over 100 years of expertise to your manufacturing supply chain. We work hard to solve your unique design-to-manufacturing challenges and will create the most effective solution for your project.

The “best of the best” of tomorrow’s skilled workforce came together at the MCEF SkillsUSA State Championship in Jackson, MS.  Over 300 participants distinguished themselves in this exciting event designed to coach, inspire, and recognize the value of careers in construction and manufacturing.

Competitors were tasked with hands-on projects in the areas of carpentry, cabinet making, residential wiring, industrial motor control, HVAC, masonry, plumbing, sheet metal, welding fabrication, structural welding, and TeamWorks. All events took place in the new Mississippi Trade Mart, and the match-ups were fierce! Timed heats included both individual and team projects. Spectators could feel the energy, talent, and focus that emanated from the contenders as they dove into challenging tasks designed to showcase their skills and craftsmanship. 

Collaboration was key as the Mississippi Construction Education Foundation (MCEF) together with the Mississippi Department of Education and over 87 local and national industry partners jointly hosted the state championship. The action-packed, two-day event brought together students from high school, community college, and apprenticeship craft programs who competed for prizes, scholarships, and a spot in the National Leadership and Skills Conference to be held in Atlanta, GA in June. 

Taylor Machine Works and O’Neal Manufacturing Services were proud to be among the industry partners and contractors who provided materials, funding and in-kind assistance for the event.  Many sponsors participated in the competition as judges, project managers, and facilitators. 

A nonprofit national education association, SkillsUSA supports personal, workplace, and technical skills grounded in academics. The mission of MCEF is to train, promote careers, and recruit a quality workforce for the construction industry in Mississippi. The alliance of MCEF, SkillsUSA, and industry partners recognized the next generation of doers and reminded all that the future of America’s skilled workforce is in the hands of the students of today. 

OMS-Greensboro recently held a professional facility tour for local educators and members of the business community as part of the GIIT program, which strives to improve workforce and economic development in Guilford County, NC.  O’Neal Manufacturing Services hosted the event as part of a joint effort with the Greensboro/High Point Chambers and Guilford County Schools.

Matt Moon, general manager of OMS-Greensboro, discussed manufacturing industry trends and fabrication operations he oversees in the North Carolina plant.  Participants walked through the 226,000 sq. foot industrial equipment fabrication facility and gained insight into the skillset of our employees, our company culture, and how academic and technical planning can connect students and others to jobs in advanced manufacturing & engineering.

O’Neal Manufacturing Services showcases an extensive lineup of equipment and experienced personnel to support original equipment manufacturers in the construction and heavy equipment industry.

The FABRICATOR’s prestigious Industry Award is given to a company or individual in the metal forming and fabricating industry that has successfully improved operations, attained business growth, and contributed to both the local and industrial communities. O’Neal Manufacturing Services is honored to be recognized by the Fabricators & Manufacturers Association with this esteemed award. 

“It’s wonderful to be acknowledged by such a respected organization,” responded Kent Brown, President, and CEO at O’Neal Manufacturing Services.  “Our team works very hard to maintain a culture of quality, safety, and integrity that I believe is truly transparent to the customers we support, the staff we have built at each of our facilities, and within the communities we serve.  We have been fortunate to achieve a high level of success over the past year and look forward to providing innovative solutions that create the best value for our customers for many years to come.”

As one of the largest family-owned metal fabrication companies in North America, O’Neal Manufacturing Services (OMS) prides itself on providing reliable, high-quality, solution-driven services for large original equipment manufacturers and contractors. Whether driven by the need for increased production capacity, condensed launch-to-market schedules, or shelter from supply chain risks, OMS offers strategic, long-term benefits for its customers through project management and industrial equipment manufacturing support.

The FABRICATOR’s 2022 Industry Award criteria include operations milestones focused on shop floor improvements, safety, and training; marketplace achievements including business success, customer satisfaction, and new products/services; and community involvement such as philanthropic activities and the support of manufacturing as a future career choice. The winner is selected by an awards committee consisting of staff and members of the Fabricators & Manufacturers Association, International. 

Congratulations to O’Neal Manufacturing Services’ Monterrey facility for being selected as the Putzmeister 2021 Supplier of the Year for the North American region! OMS was selected for its ability to deliver parts efficiently, on time, and at the highest level of quality. Jim Boldrey, Head of Global Procurement for Putzmeister, commented that O’Neal Manufacturing Services has supported their organization beyond its expectations. “We’ve learned that flexibility and agility are now key priorities to properly adapt to our new normal.”  Boldry added, “We are extremely grateful to have O’Neal (Manufacturing Services) as a partner to support our business!”

Located at the industrial center of Mexico, O’Neal Manufacturing Services-Monterrey is a powerhouse in multi-step processing and machined assemblies. At 240,000 square feet, our state-of-the-art production facility boasts a wide range of precision welding, metal forming, and heavy metal fabrication equipment. From custom design to painted finishes, we pride ourselves as the all-in-one source for high-quality metal fabrication services.  

Upon receiving this prestigious recognition, Esteban Garza, General Manager for OMS-Monterrey responded, “Achieving this award from a company so important represents a big success and a great deal of satisfaction from everyone on the team.”

At O’Neal Manufacturing Services, we form strategic partnerships with OEMs, serving as an extension of their company and producing creative and effective solutions for their unique manufacturing needs. We are honored to receive this distinguished award and look forward to our continued partnership. #LetsBuildThings  Read More About OMS-Monterrey