Close labor gaps with force multipliers

Machine shops large and small are struggling with unprecedented labor shortages and economic pressures.

If governmental publications are correct, we will continue to face labor shortages into the foreseeable future because not enough skilled craftspeople are in the pipeline to support demand.

Economic pressures as a result of inflation and bottlenecked supply chains are driving up costs, pulling down margins and exacerbating labor shortages. Now more than ever, machine shops are seeking ways to increase productivity and reduce costs without additional labor.

Machinists and engineers usually respond to the need for improved productivity and lower costs by trying to machine parts faster. We often default to new drills, endmills or other tools that make chips more quickly, and most of the time these things provide productivity gains.

However, machining faster seldom closes the entire cost gap and has almost no impact on labor constraints. If we are going to significantly impact productivity and close labor gaps, machine shops must find more creative solutions.

Military science presents the concept of a force multiplier, which is defined by the Cambridge Dictionary as “something that increases the effect of a force.” Modern shops need to find tools and technologies that allow machinists to complete more value-added work without increasing the necessary resources. We need to find force multipliers. Taking advantage of them at a machine shop is the most effective way to reduce costs through improved productivity.

Anytime we can give a tool to a machinist that allows him or her to effectively conduct multiple simultaneousoperations, we have created a force multiplier.

Everyone knows that the only time a machinist is productive is when a machine makes chips. Chip making is value-added time. We all agree that setups, tool changes and all similar activities, necessary or not, are non-value-added time. Anytime we can give a tool to a machinist that allows him or her to effectively conduct multiple simultaneous operations, we have created a force multiplier.

One of the most effective and often overlooked strategies to improve productivity is reducing non-value-added time invested in raw materials. Preparing them for machining operations is usually a lower-skilled job with generous tolerances, making them perfect for applying creative tools as force multipliers.