Automation in Manufacturing — How PMI Uses Robotics to Improve Quality, Safety, and Scale

When to Bring Your Manufacturer In (Hint: It’s Earlier Than You Think)

In this episode of the Fabricated Metals Podcast, hosts Dana Hansen and Chris Conard dive into a critical—but often overlooked—aspect of manufacturing success: timing. More specifically, when to bring your manufacturing partner into the process. Drawing on over 20 years of industry experience, Dana and Chris explain why involving your fabrication partner earlier than you think can significantly reduce costs, shorten lead times, and prevent costly redesigns. From material selection and tooling strategies to tolerancing and part geometry, they break down how early collaboration leads to smarter, more efficient production outcomes. The conversation highlights real-world examples of common pitfalls—like over-engineered tolerances, hard-to-source materials, and late-stage design constraints—that can stall projects and inflate costs. By contrast, early supplier involvement opens the door to better decision-making, improved manufacturability, and more scalable solutions. If you’re an engineer, designer, or procurement professional looking to streamline production and avoid unnecessary delays, this episode offers practical insights you can apply immediately. Timestamps 00:00 – Introduction to the Episode Overview of the podcast and today’s topic: when to bring in your manufacturing partner. 00:00:33 – Why Timing Matters More Than You Think Dana and Chris introduce the idea that earlier collaboration leads to better outcomes. 00:01:24 – The Value of Early Design Collaboration How manufacturers can support engineering and design teams from the start. 00:02:00 – Real-World Example: Reviewing a Customer Print Common issues found in initial designs and how they can be improved. 00:03:10 – Material Selection & Cost Implications Why choosing the right material early can prevent sourcing challenges and reduce costs. 00:04:40 – Choosing the Right Manufacturing Process Stamping vs. fabrication, laser cutting vs. punching—what to consider. 00:05:33 – The Problem with Over-Tolerancing How overly tight tolerances increase costs and complicate production. 00:07:33 – Material Callouts & Procurement Challenges The risks of specifying uncommon or unnecessary materials. 00:08:22 – Tooling Strategies & Production Efficiency How tooling decisions impact scalability and labor costs. 00:09:28 – Tooling Lead Times & Planning Ahead Why early decisions help avoid delays in production schedules. 00:10:00 – The Cost of Waiting Too Long How late-stage changes lead to expensive and time-consuming revisions. 00:10:45 – PMI’s Partnership Approach How the team supports customers throughout the design and manufacturing journey. 00:11:30 – Final Thoughts & Key Takeaways Encouraging early collaboration to drive better results and cost savings. Key Quotes * “It’s so much better when we can be part of the process as early as possible.” * “You have the most latitude to make changes early on in the design phase.” * “Many times, the tolerances are literally too tight to manufacture.” * “When we’re delivered a print and told it has to be this way, now we’re limited.” * “Time is money—and waiting too long costs both.”   Relevant Links Resources Mentioned * Fabrication Buyer’s Guide: https://www.pmillc.com/guide/ [https://www.pmillc.com/guide/] Let’s Connect * Process Metals Innovators (PMI): https://www.pmillc.com/ [https://www.pmillc.com/] * Dana Hansen on LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/ [https://www.linkedin.com/in/dana-hansen-46a61114/] * Chris Conard on LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/ [https://www.linkedin.com/in/chris-conard-bb2b5016/]

Saving Smarter in Metal Manufacturing: Why True Cost Reduction Starts Before the Quote

In this episode of the Fabricated Metals Podcast, host Dana Hansen sits down with Chris Kennard, Denny, and Dan from Process Metals Innovators (PMI) to explore what real cost savings look like in metal manufacturing—and why focusing on part price alone often misses the bigger picture. The conversation starts with a common challenge: most customers begin with a request for a quote, but true savings are driven by much more than price. The team breaks down how design decisions, logistics planning, inventory strategy, and waste reduction all play a major role in total cost. From LTL versus full truckload shipping to PMI’s in-house trucking fleet, Denny explains how delivery control, timing, and returnable packaging directly impact both cost and customer experience. Dan brings a process-planning perspective, highlighting how over-tolerancing, unnecessary GD&T, outdated drawings, and vague print notes can dramatically increase cost without improving part function. Small adjustments—like replacing welds with bends, using tabs for alignment, or forming features directly on a punch—can eliminate extra handling and reduce labor. The episode wraps with a broader look at PMI’s end-to-end manufacturing capabilities, including stamping, fabrication, machining, powder coating, and inventory management. The key takeaway is clear: savings come from partnership, not just price. When manufacturers engage early and plan holistically, they unlock faster lead times, lower total cost, and more reliable outcomes. ⏱️ Timestamps 00:00 – Welcome to the Fabricated Metals Podcast 01:10 – Why customers focus on price first 02:00 – Logistics as a hidden cost driver 02:33 – LTL vs full truckload shipping explained 04:25 – Risks of LTL: delays, handling, and damage 05:20 – PMI’s in-house trucks and delivery reliability 05:45 – Returnable packaging and waste reduction 06:30 – Custom racks and warehouse space savings 07:30 – The true cost of expediting shipments 08:55 – Safety stock and quick-ship strategies 09:10 – Over-engineering and tolerance issues on prints 11:00 – GD&T, ISO tolerances, and manufacturability 13:00 – “Break all sharp edges” and costly print notes 14:20 – Reducing welding with bends and interlocking tabs 16:30 – Punch vs laser vs stamping: choosing the right process 19:40 – Importance of solid models and clean CAD files 21:30 – PMI’s end-to-end manufacturing flexibility 23:00 – Stacking, batching, and vendor-managed inventory 24:30 – Why warehouse space is an underrated cost 26:50 – Final takeaway: savings come from early planning 💬 Key Quotes * “Savings come from partnership, not just price.” * “A simple note on a print can turn a three-dollar part into a much more expensive one.” * “When it goes on a PMI truck and we say it’ll be there at 10, it’s there at 10.” * “Over-tolerancing is one of the most common and costly issues we see.” * “Real cost reduction starts in the design phase, not after production begins.” 🔗 Relevant Links * Process Metals Innovators (PMI): https://www.pmilc.com [https://www.pmilc.com] * Free Fabrication Buyer’s Guide: https://www.pmilc.com/guide * Follow the Fabricated Metals Podcast for future episodes

Automation in Manufacturing — How PMI Uses Robotics to Improve Quality, Safety, and Scale

Automation is no longer a future concept in manufacturing — it’s a competitive necessity. In this episode of The Fabricated Metals Podcast, host Dana Hansen is joined by Eric Lewis, Plant Manager at PMI, and Chris Conard, President of PMI, to explore how automation is reshaping modern metal fabrication. From PMI’s first ABB welding robot to collaborative robots (cobots), advanced stamping automation, linear transfer systems, and high-volume tapping cells, this episode breaks down how automation improves consistency, ergonomics, and throughput — without replacing skilled workers. The conversation highlights how PMI evaluates which processes make sense for automation and how robotics help address ongoing labor shortages across the manufacturing industry. You’ll also hear how safety systems, vision technology, sensors, and controls are critical to successful automation, as well as why partnering with experienced automation providers is key to long-term success. Whether you’re a manufacturer considering automation or a buyer evaluating suppliers, this episode offers practical insight into how smart automation supports scalability, reliability, and quality. Timestamps 00:00 – Welcome to The Fabricated Metals Podcast 01:00 – Why PMI views automation as a tool to enhance craftsmanship 02:30 – PMI’s first automation investment: the ABB welding robot 04:30 – Labor shortages, ergonomics, and consistency driving robotic welding 07:00 – Transitioning to cobots and easier programming 10:00 – Automating stamping lines with multi-robot systems 13:00 – Maintenance, training, and safety challenges in automation 15:30 – Linear transfer systems and increased production speed 18:30 – New automation cells for tapping and assembly 21:30 – Safety considerations and laser welding technology 24:00 – How PMI identifies processes that should be automated 27:00 – Training employees to work alongside automation 30:00 – Why automation improves consistency and customer confidence 33:00 – Closing thoughts and preview of the next episode Key Quotes * “Automation isn’t about replacing people — it’s about enhancing craftsmanship, consistency, and speed.” * “Robots don’t get tired, and they don’t vary from part to part — that consistency matters to customers.” * “If the volume is there and the process is repetitive, automation becomes a smart investment.” * “Our employees didn’t lose jobs — they gained new skills and new career paths.” * “Consistency and quality are the biggest advantages automation brings to our customers.” Relevant Links Resources Mentioned * Fabrication Buyer’s Guide: https://www.pmillc.com/guide/ [https://www.pmillc.com/guide/] Let’s Connect * Process Metals Innovators (PMI): https://www.pmillc.com/ [https://www.pmillc.com/] * Dana Hansen on LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/ [https://www.linkedin.com/in/dana-hansen-46a61114/] * Chris Conard on LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/ [https://www.linkedin.com/in/chris-conard-bb2b5016/]

Building the Future: How PMI’s Training Center Is Shaping the Next Generation of Fabricators

Every great product begins with people. In this episode of The Fabricated Metals Podcast, we dive into how Process Metals Innovators (PMI) is preparing the next generation of skilled professionals through its brand-new training center. Designed to blend classroom instruction with hands-on experience, this initiative is transforming how employees and students alike engage with manufacturing. In this conversation, host Dana Hansen is joined by Chris Canard and Travis Parent, PMI’s Training Coordinator, to discuss how PMI University, school partnerships, and youth apprenticeship programs are building a stronger, smarter, and more connected workforce. Tune in now! Key Highlights from the Episode: [00:00] Welcome and introduction to the show [01:00] Why PMI built a dedicated training center [02:30] How training supports employee retention and engagement [03:30] The creation of PMI University [05:00] Travis’s military background and passion for teaching [06:00] Hands-on learning: welding, CAD design, and machine training [08:00] Leadership, communication, and soft skills development [10:00] Partnering with local high schools and technical colleges [12:00] Student projects: fire pits, park benches, and reverse engineering [14:00] Collaboration with CVTC and the mobile welding trailer [16:00] How youth apprenticeships lead to national recognition [18:00] Changing perceptions of manufacturing careers [21:00] Opening pathways to real-world opportunities [23:00] How training supports PMI’s customers amid labor shortages [25:00] Introducing automation, robotics, and AI into training [27:00] The importance of cross-training and employee development [30:00] How PMI’s culture of learning drives excellence [31:00] Inviting schools and manufacturers to collaborate [32:00] Wrap-up and closing thoughts Notable Quotes: “It’s not just steel that’s important to us—it’s our people.” — Dana Hansen “Training helps people feel important. It keeps them engaged and makes them want to stay.” — Chris Canard “We’re not just teaching skills; we’re building confidence and curiosity.” — Travis Parent “The more employees understand the ‘why’ behind what we do, the more engaged they become.” — Chris Canard “Our investment in training is an investment in the future of American manufacturing.” — Dana Hansen Resources Mentioned: Fabrication Buyers Guide: https://www.pmillc.com/guide/ [https://www.pmillc.com/guide/] Let’s Connect: Website: https://www.pmillc.com/ [https://www.pmillc.com/]Dana’s LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/ [https://www.linkedin.com/in/dana-hansen-46a61114/]Chris’s LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/ [https://www.linkedin.com/in/chris-conard-bb2b5016/]

How PMI Partners to Solve Your Supply Chain Issues

Every great product begins with a promise—but that promise can quickly unravel when supply chain problems stand in the way. Missed deadlines, scattered suppliers, and costly delays don’t just disrupt operations; they jeopardize trust and growth. Instead of battling constant roadblocks, imagine having a clear, reliable path that frees your time, eliminates inefficiencies, and ensures your projects run smoothly from start to finish. In this episode of the The Fabricated Metals Podcast, we talk about how PMI can help eliminate some of your supply chain issues, what makes us unique and positions us as a reliable supplier, and how we can turn many of your biggest problems into lasting solutions. Tune in Now! Key Highlights from the Episode: [00:01] Introduction to the show [00:57] Who PMI is and why customers trust them [02:04] How PMI stands out from other vendors in the supply chain  [05:24] How PMI has grown based on the different markets it serves [07:41] Ways PMI can simplify your supply chain [08:22] Real-life customer story: how PMI delivered solutions [11:49] Pain points of sourcing parts overseas—and PMI’s solutions [14:12] How PMI delivers exceptional customer service  [16:10] Automation at PMI and how it helps meet demand [17:20] A quick recap and how to take the next step [19:05] Wrap-up and end of the show Notable Quotes:  * “You are very busy when you have too many suppliers.” * “Don’t be afraid to ask for anything; let’s know what issues you’re running into with different types of parts.” * “If we can’t solve your problem, we can find someone who will.”    Resources Mentioned:  Fabrication Buyers Guide: https://www.pmillc.com/guide/ [https://www.pmillc.com/guide/] Let’s Connect: * Website: https://www.pmillc.com/ [https://www.pmillc.com/] * Dana’s LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/ [https://www.linkedin.com/in/dana-hansen-46a61114/] * Chris’s LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/ [https://www.linkedin.com/in/chris-conard-bb2b5016/]