How does the metalworking industry work?

Metalworking is one of the oldest and most important industries, which has been continuously developing and technologically advancing since the beginning. The processes implemented by companies in this industry also have a huge impact on other sectors of the economy – from automotive, through aviation and the machine industry, to construction. How does the metalworking industry function, what challenges should be expected and how do CMMS systems help solve them?

Metalworking Industry – Key Support for the Industry

In its most general sense, metalworking encompasses all processes aimed at changing the shape, dimensions or properties of metals to adapt them to the needs of the end user. It is therefore not only an important area as a stand-alone sector, but also an indispensable support for practically every other branch of industry.

Depending on the expected results, processing can be performed using many different methods, which can be grouped, for example, as follows:

• machining – involves removing parts of the material to obtain a specific shape or elements with specified parameters, including turning, milling, drilling and grinding;
• plastic processing – its purpose is to change the shape but without removing material, e.g. forging, rolling and stamping;
• heat treatment – ​​uses high temperature to change the parameters of the material, it includes, among others, hardening, annealing and carburizing;
• surface treatment – ​​focuses on adjusting the appearance and characteristics of the surface, including e.g. galvanization, polishing or powder coating.

The great importance of the metalworking industry in the broader context of the industrial sector is primarily due to its versatility, as well as the possibility of obtaining components of high precision and durability. Using modern technologies, it is possible to quickly and efficiently obtain components of complex shapes, in accordance with high requirements for their parameters. Parts of this type are essential in advanced industrial applications, which additionally emphasizes the role of machining.

Operational Challenges in the Metalworking Industry

Due to its strategic importance, the metalworking industry regularly faces a number of operational challenges. They can affect both the efficiency and competitiveness of plants, but at the same time they can also be a driving force for technological change. Among the greatest challenges, it is certainly worth pointing out the constantly growing requirements for precision and quality – modern industry, especially in sectors such as aviation or medicine, requires exceptional accuracy and repeatability. Even small deviations in the production process can lead to financial losses or customer dissatisfaction, which is why companies involved in machining must use modern methods, e.g. CNC machines. In addition, it is worth paying attention to the high level of operational complexity, especially in the context of processes requiring the integration of various activities , such as cutting with heat treatment.

The risk associated with machine downtime cannot be ignored either. The lack of availability of individual devices can generate not only additional costs, but also problems with the implementation and timeliness of orders. For this reason, specialist maintenance solutions are needed – e.g. CMMS systems integrated with IoT sensors . Moreover, in order to efficiently handle machining processes, a qualified workforce with specialist knowledge and skills is necessary. This is another source of considerable costs – in addition, there is also a strong dependence on the prices of raw materials and energy, which forces companies to look for ways to optimize processes, including through automation .

Maintenance of metalworking operations – machine maintenance

The machines currently used in the metalworking industry – such as CNC lathes, milling machines or hardening furnaces – provide a very high level of precision, but at the same time require regular maintenance. The results of individual processes depend to a large extent on the technical efficiency of the machines, which must operate with maximum accuracy to avoid potential deviations in production. Regular maintenance helps prevent damage to tools and machine components, which translates into a reduced risk of unplanned downtime and maintaining repeatability of processes. An additional benefit is the increased service life of the machines, and consequently a reduction in the costs associated with emergency repairs. All this means that modern maintenance solutions play a special role in the context of machine processing.

Types of Maintenance in the Machining Industry

Depending on the needs and current situation of a given plant, different approaches to machine maintenance can be used. There are three main strategies: preventive, predictive and reactive maintenance. The latter involves repairing machines only after a failure has occurred, which is usually not an optimal solution, but in some cases it may be necessary – especially in emergency situations. Predictive maintenance, on the other hand, focuses on using data from sensors and monitoring systems to predict potential technical problems. With access to such information, service activities can be carried out exactly when they are needed. Preventive maintenance, on the other hand, involves regular inspections and replacing worn parts according to a set schedule to prevent failures before they occur. A comprehensive approach to maintenance should primarily include preventive and predictive maintenance, but space should also be left for reactive activities in crisis situations. Among the tools supporting maintenance, it is worth paying attention to CMMS systems, IoT sensors, diagnostic systems and software for analyzing technical data.

CMMS – essential support for the metalworking industry

CMMS (Computerized Maintenance Management System) software is a key source of support in managing maintenance and service processes in industrial enterprises. In the metalworking industry, their use is mainly aimed at minimizing machine downtime and improving spare parts inventory management – an additional benefit is also the optimization of maintenance activities based on real data.

CMMS enables, among other things, automatic planning of preventive maintenance based on actual machine wear, as well as quick identification of potential problems through integration with IoT sensors. Sensors can monitor parameters such as temperature, pressure and vibrations, and pass them on to the system, where they are analyzed for early detection of anomalies. In addition, CMMS systems offer advanced tools for spare parts management, which allow, among other things, tracking the status of stocks in real time or automatically generating orders. They can also be used to optimize stock levels to avoid both shortages and surpluses. Effective management of spare parts stocks is crucial in this type of industry, where the response time to a failure often has a decisive impact on maintaining production continuity.

CMMS functionality can also include automation of maintenance processes. In particular, we are talking about generating work orders for technicians based on schedules or sensor data, as well as tracking the progress of maintenance work in real time. CMMS software also allows for the analysis of data regarding the cost and time of service activities. All this translates into significant improvements in the work of maintenance departments, which in turn has a significant impact on the functioning of the entire industrial enterprise. As a result, CMMS systems are currently the basic digital tool in the metalworking industry and beyond. If you want to learn more about this type of solution, please contact us – we prepare comprehensive implementations for companies with different profiles, taking into account the individual requirements and production conditions in individual plants.

The metalworking industry – the foundation of the modern industrial world

The metalworking sector is of great importance to the functioning of other areas of industry, because it supplies components necessary for the implementation of production processes. However, the efficiency of operations in this field depends to a large extent on the ability of companies to meet the increasing requirements for quality, precision and operational efficiency.

In maintaining the continuity of production and quality, machine maintenance plays a very important role, which is a fundamental part of maintenance. In this area, a number of modern technologies and digital-hardware solutions are used – including IoT sensors and CMMS systems. Using CMMS software, you can, among other things, minimize downtime, automate maintenance processes and optimize the management of spare parts inventories. All of these tasks lead to higher efficiency and competitiveness of plants in the metalworking industry. In addition, in the future, we can expect a further increase in the importance of automation and data analysis solutions – this means that it is worth investing in a modern approach to maintenance now. We encourage you to contact our specialists to learn more about available solutions for the industry.