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What’s The Difference Between Metal Fabrication And Welding?

Metal fabrication refers to the processes and techniques required to design, create and assemble a metal structure. While welding — or using heat and pressure to fuse metal-based materials — is an essential component of the metal fabrication process for some projects, using the terms welding and metal fabrication interchangeably is like using the words fireplace and living room interchangeably. Although fireplaces are recognizable features of living rooms, they’re only one part of those rooms!


You Can’t Afford Not to Focus on Reducing Needless Costs

A regular part of being a business owner is identifying areas of your business where you can trim expenses and needless costs. Key areas you should look at are your vendor and partner relationships. 


Case Study: Increase Efficiency, Increase Cash Flow

Mainstay takes efficiency and adaptability seriously. We consistently invest in machinery and floor space. We follow streamlined processes that match any level of demand. We constantly pursue improvement. These commitments allow us to provide high-reliability metal fabrication and machining for our partners, but they don’t stop there.   (more…)

Why ‘You Can’t Afford Not to’ Is a Universal Business Concept You Should Apply to Your Vendor Relationships

When my partner and I started our company, we wanted to be the best. We didn’t start out by buying bargain equipment or hiring the cheapest workforce. We focused on buying the best equipment and investing in the top people because we felt that to reach the level we wanted, we couldn’t afford not to. 


High Reliability

To Be a High-Reliable Organization You Must Partner with High-Reliable Organizations

Mainstay invests and plans strategically to provide a high-reliable relationship. In our industry, if you’re not highly reliable, you’re a poor commodity, risky bet or worse, forgettable. You must be able to reliably move products from manufacturer to consumer confidently at or above expectations or you lose to the competition.  (more…)

Advantages and Disadvantages of Laser Cutting

Laser Cutting
Laser cutting is one of the most precise methods of cutting a design from a variety of different materials. The CNC machine, which does the cutting, is programmed to cut whatever design the client wants. From simple rectangles to precise, intricately designed pieces, laser cutting is your best option for most applications.


Increase Cash Flow

Lack of cash is very expensive. That might sound counter-intuitive, but what it means is that a lack of cash will choke and cripple a company. The smaller the organization, the more obvious the impact of poor cash flow. The bigger the organization, the slower the behaviors of responsibility may be.


Uptime Efficiency

Throughput expectations are used in most production organizations. Some organizations have a throughput expectation without any planning to support the expectation. Other organizations plan throughput goals without collaborating with their internal and external suppliers to learn efficient supply quantities and frequency to better establish fair expectations. No matter what, you had better have at least some kind of an idea on the amount of material or items passing through your organization. 


Inventory Reduction

Over the decades of working with our partners to create growth and build our relationship, we’ve discovered that the majority of our partners consistently deal with fat inventory due to working with unreliable vendors

Idle inventory is dangerous, and the longer you hold onto it, the greater the risk of seeing it sit longer, get damaged or never move at all—each affecting your cash flow.


Leading the Conditions for Innovation

Innovation is easier to understand and apply to a product than a process or service. The process of improving a product or anything that is tangible comes easier given that it can be used and determined as easy or difficult. 


Metal Fabrication And Machining Job Opportunities in Indiana

Metal Fabrication And Machining Job Opportunities in Indiana

A career in metal manufacturing in Indiana offers many opportunities for varied and sustained growth. There are few barriers to pursuing the field, particularly if one is skilled at reading and mathematics. 

Many entry-level metal manufacturing opportunities exist for those with a GED. Metal manufacturers, fabricators and welding tradesmen are often in high demand and can expect a reasonable wage for their labor. 


Metal Fabrication and Machining Manufacturing: How We Stay Competitive in 2020

Anyone who works in metal fabrication and machining manufacturing can tell you: working in this business isn’t easy. It takes an expert-level skill set and specialized machinery to do it right. Sustained growth can be difficult for many manufacturers, especially ones who only serve specialized markets. And sometimes, once you’ve finally found a manufacturer who serves your needs at a fair price, they go out of business, don’t have the equipment you need or can no longer work within your budget. 


Driving Organizational Change

Organizational change within any business is a cooperative undertaking. At Mainstay Manufacturing, our mission and business philosophy have always included the importance of shared outcomes (and shared responsibilities) with our employees and partners-in-growth. 

Mainstay Manufacturing’s success over the past twenty years stems from the knowledge that all of our employees have important jobs to do. Our work, from start to finish, has always been cooperative and symbiotic in nature but led by the leaders of the organization. The high quality of our work is a reflection of our values as a company and a reflection of just how highly we value your business. 

Change is inevitable and we embrace it. Like any business, Mainstay is competitive. We want to see our work succeed and that’s where organization change comes into play. It’s a way of taking our work from one level to the next level to satisfy the needs of our partners and achieve important and meaningful goals.

Our Leadership Process

Unlike most other manufacturers, our employees (and partners) are empowered and valued throughout the structure, nature and processes behind our leadership. For us, good leadership isn’t hard. It’s about inspiring our employees to come up with innovative solutions to solve complex problems. 

This is a collaborative process. Our employees are continuously challenged to reflect upon our strengths and weaknesses as a business. What are we doing best? What organizational changes need to happen, and why? What actions can each team member take to ensure these changes are implemented fairly and to the best of our ability? It’s a process filled with questions and discussions until the right answers and strategies are devised to reach our and our partner’s goals. 

Our employees (and partners) are empowered and valued throughout the process by our leadership. Our leaders facilitate change so that everyone down the line can execute a strategy that achieves internal and external goals.

Making Change Work

At Mainstay Manufacturing, we think of organizational change as a kind of partner dance. Both parties are equally responsible for the overall performance, but the lead is responsible for driving and guiding the changes within the dance. 

Both the lead and the follow need to clearly communicate and continuously practice awareness of each other’s movements. Both parties need to want to work together and agree upon the timeline for the dance. But the lead is responsible for providing the cues that really drive the performance, thinking several steps ahead while seamlessly incorporating the unique skills and capabilities of the follow. 

Our leadership team at Mainstay Manufacturing works a bit like this. We strive to empower our employees by utilizing their individual strengths, recognizing the significance of their contributions, and using this information to navigate and drive our success as a business. 

Meaningful work is proud work. At Mainstay Manufacturing, our high standards for success are met each day thanks to excited and empowered people. If that isn’t something to feel proud of, then tell us what is. Our team will always seek to adapt and evolve so that we can work better for our partners and better for ourselves. Looking for a manufacturing company that can adapt as you do? Contact us today. 

Servant Leadership

To everyone at Mainstay Manufacturing, servant leadership isn’t just another catchphrase or buzzword to grab new clients. Mainstay Manufacturing’s growth as a company has largely been determined by our success in creating strong, sustained partnerships. We care about the quality, efficiency and purpose of our work, and our clients know this. That’s why they continue the partnership for mutual growth.  


What is the Trumpf L3030 Fiber Laser?

At Mainstay, we use only the best technology for laser cutting steel, stainless steel, and aluminum. We strive for continuous improvement in the quality and efficiency of our laser cutting process. Laser cutting equipment is a key factor in the laser cutting procedure, and we choose only the top of the line tools and technology for our laser cutting. To meet new demands, we invest in new cutting-edge Trumpf equipment every three years. One of our most recent investments, the Trumpf L3030 Fiber Laser, has drastically improved our cutting capability and capacity. 


The Origins of CNC Machining

Computer numerical control, or CNC, machining, is an important process used throughout manufacturing and production. While CNC machining is a modern manufacturing process used for complicated machinery, its origins can be traced back to the older, basic concept of numerical control. Here we break down the fascinating history and origins of CNC machining.  (more…)

Managing Change

If you’re going to make a change in your business, there must be a reason for it. Don’t make changes for the sake of it, but rather to follow a plan for improvement. The main reason to implement a change is to fix a specific problem or to improve an important relationship with an employee, department, vendor, or customer. (more…)

Fighting the Curse of the Stepping Stone Business

Always be recruiting!

Smaller businesses should expect their employees to move along and advance to the next steps within a two, three, or four-year period. The best people in your organization will eventually grow into new responsibilities. If your business doesn’t support their personal growth goals, they will move on. On the other hand, if the business owners foster that evolution and plan for their best individual’s needs, the business will offer opportunities that allow for personal development.


The Comprehensive History of Laser Cutting

Laser cutting is a popular fabrication technology that uses an exacting laser beam to cut materials, such as aluminum, carbon steel, glass, plastic, stainless steel, superalloys and wood, into custom shapes and designs. Known for its precision and efficiency, laser cutting presents a reliable solution for machining geometrically-complex projects.


Types of Metal Fabrication

Without the expertise of metal fabricators, we would be without many products that keep our lives running smoothly. Some everyday objects made from durable metals include tables and chairs, hand tools, automobile parts, nuts and bolts, pipes, structural elements for buildings, and other equipment.

Metal fabrication involves the cutting and shaping of metal, which will soon be assembled and formed into a product. This includes plate metal, formed and expanded metal, hardware, fittings, sectional metal, welding wire, and so many more. Read on to learn more about this fascinating process.


Principles of Laser Cutting

Laser cutting is a mysterious and fascinating feat of science that may seem impossible to explain. How can a single beam of light cut through some of the thickest and toughest metals? While there are several different methods of laser cutting, the basic process can be simplified enough for anyone to comprehend.

This guide will help you understand what laser cutting is and how the manufacturing industry utilizes it to cut and shape sheet metal and other materials into the products we use daily. 


Let Us Be Your Mainstay

Mainstay Manufacturing provides parts and components machining services to Midwest manufacturing companies looking to streamline their production for greater profitability. Our flexible processes and ever-adapting capabilities allow us to match your needs no matter how large your supply demands may grow. 


Metal Fabrication Tools and Techniques

Whether for tools, jewelry, or military applications, humans have been manipulating metal for thousands of years. The art of metal manipulation thrives on today. While it’s fun to enjoy using things we can make with metal, you may also find it interesting to learn what goes into the metal fabrication process. Read on to learn more!


Quality Assurance vs Quality Control

When embarking upon a project that involves intense metal fabrication processes, the first thing you will want to ensure is that you receive a high quality product from your fabrication service provider.


What is CNC Machining?

CNC, or computer numerical control, machining is a modern manufacturing process that creates a part from a computer design file. CNC is a subtractive process, meaning it removes material from a stock, or blank, piece to produce a custom part. CNC machining works well with many different materials, including metal, wood, glass, plastic, foam, and composites. Highly versatile, CNC machining is used in numerous industries including automotive, construction, aerospace, agricultural, and more. Products like automobile frames, airplane engines, surgical equipment, and garden tools can all be created from CNC machining.  (more…)

Tips for Working With an Out of State Metal Fabricator

Although it can seem intimidating to use an out-of-state fabricator for your large metal fabrication projects, the location should not be a limiting factor in selecting a metal fabricator. Don’t let location decide who you will work with, but it is important to be thorough when selecting an out-of-state metal fabricator. Before working with a fabricator outside of your area, be sure to follow the tips below.  (more…)

Sheet Metal Fabrication 101

Take a look around Indianapolis. What do you see? No doubt steel buildings standing tall, and cars zooming past. But how are they made? 

Sheet metal fabrication is not just used for construction or commercial products, but for all the tools and machines we see and use every day. The process involves many different steps. Before beginning your own project, you should understand how it all works and what is possible through Indianapolis sheet metal fabrication.  (more…)

How to Improve Your Metal Fabrication Bids

How your business chooses a metal fabrication partner can determine the success of your next project or product launch.

It can be an overwhelming process to sort through all of the competition to try and find the right company for the job. You don’t want to put your project in the hands of just anyone. You need a company that is reputable and can effectively direct all aspects of the process.  (more…)

Signs A Metal Fabricator Is Right For Your OEM

Sometimes it can be hard to know who to turn to when looking for an OEM metal fabricator. Before choosing one, you will want to investigate to make sure that you are picking the best counterpart for your company. Metal fabrication firms can offer you an extensive range of services including creating high-quality products for your company. So, how would you know that you have chosen the right OEM metal fabrication partner for your company?  (more…)

Advantages of Precision Machining

With Mainstay’s precision machining, you can expect a highly customized product created by a combination of software, cutting machines, and specialized engineering. CNC machines can also be used to meet the exact dimensions and qualifications of a very precise project.

If you’ve been considering outsourcing your precision machining for whatever reason—maybe your own company can’t currently invest in a CNC machine, or you’re swamped with production requests—we can give you three good reasons why working with Mainstay is a great idea!  (more…)

Advantages of CO2 and Fiber Laser Cutting

Once you’ve decided to use laser cutting for your project, a whole new array of options appears. What kind of laser cutting method will serve you best? This is an important decision to make before you begin your project: should you use fiber laser cutting or CO2 laser cutting? Neither laser is a bad decision, but one might be a better fit for the material you need to have cut. Each of these lasers have advantages and disadvantages, and both should be considered carefully before making your final choice. Read on to learn more.  (more…)

Four Foundations of Effective Leadership

Great companies are not created from dust. They are built on the strong foundation of leadership skills, which are developed over time with the help of a positive and dynamic team. No one person can thrive on their own. It has taken a village to build mainstay manufacturing into the large, successful company it is today. Through great leadership, motivation, and clear communication we have risen to a target company and employees are proud to join the team.

Below are four posts focused on different leadership concepts I’ve learned over my decades of leadership experience. You can read a quick summary of each topic, or click the title to read the post in its entirety.  (more…)

You’re Not Too Busy

When I was first starting out, I felt as though I needed to be the answer man. Whenever people in my organization faced a challenge and would ask me questions, I would be thrilled to provide the answer. It made me feel competent, capable, and in control.

While it was great that I had the knowledge and experience needed to help my team, what I failed to realize was that I was hindering my productivity by answering their questions all day. I started to become too busy to take care of all of the tasks that I needed to get done. Instead of focusing on the big picture and getting results for my organization, I would scramble to find time to get things done between answering my team’s questions and providing them with guidance.  (more…)

The Power of Now

To be a successful business owner, you can’t be stuck in the “now.”

One of the biggest mistakes rookies make is using “now” as an excuse. “We can’t afford to expand our business now.” “We can’t hire any more employees now.”  (more…)

The Importance of Lateral Leadership

When I was first starting out building and leading teams in the fabrication industry, I made the mistake of trying to tackle situations on my own. I did not have partners to help me; I felt like it was up to me alone to attack the challenges I was facing.

I quickly learned that it is lonely at the top. While many people try to argue that finding success on your own is good or that it makes you elite, it is important to know that it is scary and dangerous. The problem with trying to lead on your own is that you have no one who is able to give you the advice, encouragement, and honesty you need to lead well.  (more…)

Why You Should Enable Your Team

Early in my career, I felt as though I needed to handle every responsibility that came my way. As the boss, I was reluctant to hand off tasks to my team, and I took on too many roles — even ones that were not directly related to serving my clients. I felt as though I absolutely had to do it all.  (more…)

Advantages of CNC Machining

When creating thousands of copies of the same high-quality product, conventional machines may slow your workflow. Not only do these antiquated machines require many workers, but they are difficult to learn how to operate safely and efficiently. If you want supreme precision within a short timeline, CNC machining is the way to go.


The Future of Metal of Fabrication

From the automotive to medical, aerospace to agricultural, metal fabrication in today’s economy is prevalent, necessary, and constantly evolving due to changes in technology and harder-to-find levels of skill. So to predict what the future holds for metal fabrication and fabricators, one must keep close tabs on issues that affect our industry every business quarter. (more…)

Winter’s Coming! Protect Your Inventory

When winter comes around, you take steps to protect your home and your belongings from the cold, right? You make sure door and window seals keep the cold air out, replace the furnace filter and block any other air leaks to ensure your home is comfortable and efficient. Well, you need to do the same thing for your metal components inventory.  (more…)

The Subtle Art of CNC Machining

A stack of steel bar stock rests on a rack in the shop. The plans for the part have been drawn up. The contract signed. The order made. Now it’s up to the shop to transform that raw material into the intricate components the customer expects with tolerances down to +/-.0001”. Let the subtle art of CNC machining begin.  (more…)

6 Indicators You Need to Change Suppliers

When I was growing up, I thought my mother made the best spaghetti sauce in the world. I didn’t know how she made it; I never really paid attention at that young age.  When I moved away from home and married into a family that had an obsession with Italian food, I learned that the sauce I had experienced in childhood – and thought was awesome – was just “ok” (and actually just came from a jar). The sauce that my mother-in-law made was made from scratch and truly amazing!  My wife has since carried that to the next level and it is even better, now!  (more…)

The Traits to Look for in a Full-Service Metal Components Provider

There are a lot of metal fabrication shops and machining companies out there. Many shops specialize in one area. While there’s nothing wrong with that approach, it’s limiting for their clients and partners.  (more…)

3 Most Common CNC Machining Problems

Picture this, you’re day is moving along nicely, when all of the sudden the CNC machines in your shop start to produce components that don’t meet the necessary specifications. What’s wrong?  (more…)

CNC Machining: Advantages and Disadvantages

Half a century ago, machinists were always responsible for crafting every single piece to perfection. These skills are still needed, but when it comes producing the same piece at high volume and high precision, computerized machines are vastly superior. That’s where Computer Numerical Controlled (CNC) machining comes in.  (more…)

The Challenges of Laser Cutting Aluminum and Other Reflective Metals

CO2 laser technology—the most common laser technology—operates using gas, mirrors and delicate lenses. Because of this, cutting aluminum can be extremely challenging.  (more…)

Sheet Metal Fabrication Process in Indianapolis

No matter what you need when it comes to sheet metal fabrication, one thing is certain. You need it manufactured precisely, properly, promptly and in a cost-effective way. At Mainstay Manufacturing, we do exactly this from our Indianapolis-based manufacturing facility. 


Fiber Optic vs. CO2 Laser Cutters: Which is Best for Your Business?

While CO2 laser cutting has been around for several decades, the more recent innovation of using fiber optics in laser cutters is providing new options for metal fabricators.   (more…)

Manufacturing Careers: Closing the Skills Gap in Indiana

As we touched on in two previous blog posts, the future of the manufacturing industry looks promising, both nationally and locally. This growth is, in many ways, a result of talent-driven innovation. However, the industry faces an impending setback: the shortage of that skilled talent; manufacturers are having trouble filling jobs. (more…)

Automation and the Future of Manufacturing

Technology is advancing at a remarkable rate across all industries. This advancement brings with it some anxieties but also some excitement. In the manufacturing field in particular, new technologies are ever-improving in terms of capability, flexibility and availability—bringing us ever-closer to fully-automated production facilities. (more…)

Robotic Welding: When Does It Make Sense?

Robotic welding is now one of the most common applications of automation technology in manufacturing and fabrication operations. Manual welding is a labor-intensive, highly-skilled and potentially dangerous trade. Escalating labor costs, trained operator shortages and increased competition have spurred advances in robotic welding technology. For organizations faced with these challenges, welding automation presents a real cost-saving solution. (more…)

How Laser Technology Rendered the Plasma Cutter Obsolete

Until recent years, laser cutters and plasma cutters have been considered comparable technologies with different uses, advantages and disadvantages. Thanks to advancements in laser cutting technology, however, that assessment has changed. (more…)

Troubleshooting Tips for Plasma Cutters

Many mechanical and electrical variables influence the cut quality of the plasma cutting process. This being the case, it can be difficult for an operator to troubleshoot cut quality and dimensional problems when they arise. In this blog post we discuss common sources of plasma cutter problems and offer diagnoses for different excessive bevel angles. (more…)

What is Incremental Sheet Forming?

Incremental Sheet Forming (ISF) is an umbrella term for a few variations of a sheet metal forming technique. Through ISF, a sheet is formed into the final workpiece through a progression of small, incremental and localized deformations. The sheet is generally formed by a spherically-ended indenter, which can be attached to a CNC machine and moved over a custom-designed, numerically-controlled tool path.  Flat-bottomed and parabolic indenter profiles can also be used to achieve different surface finishes and forming limits. (more…)

Indiana: National Champion of Steel Production

There are countless reasons to be Hoosier Proud. We’re home to the Indy 500, the historic St. Elmo Steak House, the Pacers and the Colts, mild Midwest manners and incredible state and county fairs. No matter what Kentucky and Illinois try to claim, Abraham Lincoln was raised in our great state. Those who “fly over” this country are missing out on some beautiful natural gems. Add this to the list: Indiana continues to lead the nation in steel production. (more…)

Metal Fabrication Trends in 2018

2018 is well underway, and, as we move forward, we must anticipate what the year may hold. Metal fabrication trends are constantly evolving as the technology and the market change and shift. In order to remain informed and proactive, the following are metal fabrication projections and trends to stay abreast of in 2018. (more…)

How We Do Laser Cutting in Indianapolis

Cutting mild steel, stainless steel, and aluminum materials can be done in a variety of ways but one of the most efficient and accurate ways to cut these types of material is by using laser cutting technology. 


Align Your Vendor Relationships: It’s Good for Business

Generally speaking, there is a simple principle for pursuing growth as a business owner: align your resources with your business strategy. Of course, when put into practice, this principle becomes increasingly complex; there are countless opportunities for strategic alignment. Essentially, you must review every aspect of your internal organizational structure and align every facet to a broader goal or budget line objective. However, it’s important to not just think internally but externally as well. In the manufacturing industry, the vendor relationship is a valuable, but often-overlooked, resource. Improving and aligning your vendor relationships will enormously contribute toward strategic growth. To that end, you need to ensure that your vendors are working with you, not against you. (more…)

Mainstay Invests in New Trumpf Fiber Laser Cutting Machine

Mainstay has invested in a new Trumpf Fiber Laser Cutting Machine. The machine’s BrightLine Fiber function guarantees high edge quality with a broad range of materials (including thick mild steel), facilitates easy part removal and produces very small holes which could previously only be drilled. This impressive machine offers increased flexibility and cost-effectiveness, cutting all sheet thickness efficiently. (more…)

Rethink Risks: How to Seek Out New Opportunities and Pursue Growth

It is impossible to be both risk averse and aggressive about growth. The two business philosophies simply cannot be reconciled. Business owners shy away from taking risks because they think about those risks as gambles endangering their bottom line: “How much capital could I lose?” However, when owners avoid these risks completely, their business stagnates and plateaus — they lose all upward momentum. If you’re a business owner truly committed to aggressively pursuing growth, you need to rethink risks. Don’t look at business risks as rolling the dice for profit and loss. Instead, reframe your mindset and look at risks as opportunities for growth. Make calculated but bold decisions in pursuit of that growth. Ask yourself: “If you’re not willing to take risks, if you’re not willing to adapt and grow, then what are you doing this for?” This blog post is intended to help you rethink risks and fearlessly pursue growth in your future business endeavors. (more…)

Managing Inventory: Invest in Your Growth

How much excess inventory currently clutters your valuable floor space? Many organizations pad their supply with extra inventory to absorb the long lead times or missed delivery dates of unreliable vendors. These organizations are attempting to overcome the inefficiencies of their vendors. However, those inefficiencies do not simply disappear: excess inventory creates an inefficiency of space and a restriction of cash flow — both essential resources. Do not allow your vendors’ inefficiencies to become your own. Invest in growth, not in precaution. (more…)

Reduce Your Vendors, Reduce Your Headaches

Many organizations utilize multiple vendors to supply their metal components. In our experience, most organizations partner with around 3 to 5 vendors. This is understandable: if a single vendor is not meeting your needs, employing multiple vendors seems to be the answer. However, multiple vendors bring multiple headaches. Partnering with someone you can trust to meet your needs and grow with you eliminates those headaches and inefficiencies.  (more…)

Strategic Solutions in Action: Relationship Case Studies

Mainstay partners with a variety of companies in a variety of industries to find specific solutions to alleviate problems and maximize efficiency and growth. We have identified six partner solutions that resonate with companies we serve.  Usually, one or two of these six stand out to be valuable solutions we focus and apply quickly.  Below, you can read specific examples we have pulled together from different relationship case studies to give you some perspective and insight.  We believe some of the experiences we share here could relate to challenges that exist in other organizations and represent opportunities afforded by our commitment to strategic solutions.


Just-In-Time Manufacturing: Eliminate Waste, Improve Productivity

What is Just-In-Time Manufacturing?

The British Motor Corporation plant in Australia originally developed the just-in-time production system in the 1950s, but it was largely adopted by Japan in the 1960s and 1970s. Post-World War II, Japan was seeking to rebuild industry but was short on cash and space. Rather than financing the big-batch, large inventory production methods used elsewhere, they built smaller factories that only housed the necessary materials to fill existing orders. This dramatically reduced inventory and investment costs. Toyota played a key role in developing just-in-time manufacturing in Japan and introducing the method to the United States; for this reason, it is often referred to as the Toyota Production System (TPS).


How to Increase Cash Flow

Investing in inventory directly affects profitability and cash flow for a business. Knowing how much to buy and when is a critical game with big gains and losses. Leaders in business must be discerning in their investments; they must make strategic decisions to limit risk and increase cash flow.

Unreliable partnerships can cause strains and restrict cash flow. Manufacturers partnering with inconsistent vendors often find themselves absorbing the costs of those vendors’ shortcomings. For example, when a vendor’s lead times are uncertain and delivery dates are missed, the manufacturer may purchase and store extra inventory to create a buffer against these issues. This extra inventory depletes the manufacturer’s cash flow and takes up valuable floor space. (more…)

How to Scale your Business for Future Growth

A business’ scalability is crucial to its success. Leaders in business ensure their business models offer the potential for economic growth and that the internal systems of their companies can adapt to meet future increases. However, it is equally important to plan for growth in a business’ outside relationships. Growth must be supported externally as well as internally.


CNC Tools of the Trade

Computer Numerical Control (CNC) references tools being controlled via computer. In the 1960s, the invention of CNC machines revolutionized the metal fabrication industry by increasing productivity and eliminating the need for constant supervision

CNC is the dominant method of machining materials today and comes in a variety of sizes for fabricating products. Below are a just a few of Mainstay’s CNC tools of the trade and their capabilities.


Laser Cutting vs Plasma Cutting

Here at Mainstay, we offer both laser cutting and plasma cutting. Thus, we often hear the question, “Which type of cutting should I use to produce my components—laser or plasma?” But the answer isn’t cut and dry. Before we delve into which method might be best for a project, let’s first take a step back and look at how each of these techniques work. (more…)

Why You Should Care About ISO 9001

As a business owner, strategic planner, or purchasing agent, part of your role is managing your vendors. While researching suppliers, perhaps you have noticed products or services referred to as ISO 9001. What does this designation mean—and why should you care about it?  

What does ISO 9001 mean?

The International Organization for Standardization (ISO) gives requirements for a company’s quality management system (QMS). Although ISO is the organization that came up with these standards, it’s important to note that they do not certify companies. ISO 9001 establishes requirements that—if executed well—empower suppliers to offer products and services that meet expectations and comply with applicable regulations.


Lessons in Leadership

In my 23 years of manufacturing, I’ve learned some valuable lessons about what to do-and not to do-that have greatly impacted how I direct the Mainstay organization and how I approach the people I work with.  Don’t get me wrong…I don’t have it all figured out.  There are many areas that I must continue to grow.  But here are some of the lessons I’ve learned throughout my years of being an entrepreneur, business owner and strategic leader.


The right people
The people you surround yourself with—from vendors to customers to employees to investors—must align with your purpose and have the same character you’re enlisting. Obviously, you need people with skills, but ethics far outweigh experience. If the people you work with don’t align with your character, you must be fair to your ultimate goal and replace them.

After you find those right people, your job is to train them, learn what motivates them, put them in positions that are best for them, point them in a direction with a clear objective and support them along the way with whatever they need: tools, equipment, training, etc. This will take them and your business far. (more…)

Getting a Welding Certificate: What You Need to Know

If you are applying to work at a welding shop, most likely you will be asked to test your skills. Larger shops will probably require you to show proof that your certifications are up to date.

Certifications are available for a variety of welding processes in order to test people’s ability to do sound welds. If you are applying for a job in MIG, TIG, or stick welding, you’ll have to reach a certain level of skill for the process before you receive your certification.


A History Lesson on Laser Cutting in Manufacturing

Laser cutting is one of Mainstay’s many offerings. We use this precise technology to create intricate features in parts for a variety of industries—construction, medical, mining, packaging, and recreation to name a few.

Because of its tight tolerances, laser cutting is an ideal solution for machining geometrically-complex features. In fact, it is more stable and accurate than any other manufacturing tool.


Mainstay Increases Capabilities with New SafanDarley Press Brake

Mainstay is thrilled to announce our recent purchase of a 13’ 200-ton SafanDarley electric press brake machine. This joins our Trumpf fleet of brake presses from 73-ton through 140-ton machines. The addition of our new machine adds flexibility and allows us to increase our capacity to better serve relationship demands.

The E-Brake technology distributes the bending force evenly eliminating the need for crowning. By removing the need for the crowning adjustment, we increase bend consistency along the length of the part. This translates to higher quality for your component needs. (more…)

An Open Letter From Clients to Supply Chain Vendors

The following satire represents common frustrations clients have with supply chain vendors. (Not us, of course. Our clients love working with us!) If you’re a purchasing agent, you can most likely relate.)

Dear Supply Chain Vendors,

It’s time we have a chat; we need to re-define our business relationship. We’ve been together for a while now, but that doesn’t mean our sales partnership is meant to last.

If you want to keep working with us, then we suggest that you step up your game. Why?


How to Upgrade your Supply Chain and Client Relationships

If you are a purchasing agent, business owner, or strategic planner, part of your role includes managing your vendors. One of the healthiest things you can do as a business is take a step back and evaluate your company’s partnerships.

Some vendors you might have been partnering with from the beginning, while others you may be trying out for the first time. As time goes on, some of those alliances will thrive. Others, on the other hand, will become more burdensome due to quality issues, increased prices, or longer lead times. In the end, you can end up putting a lot of work into maintaining alliances that don’t have a good ROI. (more…)

5 Questions Vendors Need to Answer

The metal fabrication industry needs a booster shot. Sure, you may be getting the products you need from your vendors, but don’t be content with the relationship ending there. No one’s talking about company culture alignment in the vendor/customer relationship. Now’s the time to broach the subject.

Late last year we sent out an open call to purchasing agents, business owners, strategic planners and decision makers. The goal was to host a conversation around how to create a mutually beneficial relationship between manufacturer and vendor. A relationship that is built off transparency and trust. A partnership where both companies are investing in each other towards the common goal of growth. A partnership that doesn’t necessarily happen often.


Why Your Current Fabrication Vendor is Holding You Down

Aligning with an outsourced metal fabrication vendor is a big decision, with a lot riding on it. With strict deadlines and high expectations for quality, making the right choice in a partner you can trust is paramount.

The metal fabrication industry is watered down with companies that have basic equipment, below average work ethic, and a lack of knowledge to complete the work you need to your exacting standards. These companies are out there, and they want your business, which means they’ll do whatever it takes to seal the deal.


How To Reduce The Costs of Metal Fabrication

No matter how long you’ve been in business, no matter how successful you are, there’s always something that can be done better. I’ve seen that firsthand, as I’ve worked with companies that are 100 years old, those that are just starting out and others at every stage in between. What all these companies have in common is a need to improve the efficiency and value of their products, much of which can be accomplished by reducing the costs of metal fabrication.


Top Thirteen Things to look for in a Metal Fabrication Partner

When choosing a metal fabrication partner, you’re not just buying components, you’re entering into a relationship that should be productive, supportive and communicative. A great metal fabrication partner does more than meet your production quotas. It should function as an extension of your organization that not only responds to your demands but also anticipates your needs.


When to Outsource Metal Fabrication

Precision metal fabrication equipment has become very expensive to own. Product companies need to identify their value add and concentrate specifically on those strategies. While certain equipment may be helpful in executing those strategies, it’s often not worth the cost of acquiring, operating and maintaining new equipment. If you’re looking into laser cutting or other precision methods, it’s often a good idea to consider contract manufacturing.

If product companies considering buying equipment with new capabilities don’t require two shifts of throughput for the machine, outsourcing that need makes more economic sense. Think about it: even for professional metal fabrication companies, a new piece of equipment can be very distracting. It not only costs money to purchase and set up the equipment, but you also have to dedicate time and human resources to integrating it into your production system.

Alternatively, for the same capital investment, you can enhance your value add by engineering for product enhancement, marketing for brand awareness, adding to the sales department or improving assembly, product logistics or inventory strategies within the facility. Those are all better investments than buying new capability equipment, particularly if it isn’t being used frequently enough to offset the startup costs.

It’s human nature to want to be self-sufficient. We want to do everything ourselves, particularly because it can be difficult to find someone else who can be trusted to do a job to our standards. That’s why finding a good partner is so important. Often, your organization can be exponentially improved by finding a partner with the value add specific to the capability you are considering investing in. On top of that, prioritize finding a partner who satisfies your expectations of communication, quality, delivery times, and anything else you’d expect if you were doing the job yourself. By finding a partner that you feel confident outsourcing metal to, you can improve and strengthen your manufacturing process.

Working with a metal fabrication partner to meet your throughput needs, only when you need it, streamlines your processes and ultimately improves the service you provide your customers. It can be the manufacturing solution that you’ve been looking for. More importantly, working with a partner you trust will allow you to focus on what’s going on within your facility.


Outsourcing Metal Fabrication for Safer Flights

Xwind LLC, a relatively small, Indiana-based design and development company, brings high-quality flight simulators to the people who need them most.

Designed to help pilots hone their skills safely and effectively, Xwind’s flight simulators are obviously no replacement for actual flight, but they are the next best thing to train pilots to handle dangerous crosswinds and gusts. Wind disruptions like gusts and crosswinds during flights are the leading cause of accidents every year.


Single Head Punch vs. Turret Punch in Metal Fabrication

All metal fabrication projects have similar goals: Produce quality components while maximizing both time and cost efficiency. Single-head punching technology is one of the most effective ways to attain those goals.


How Outsourcing Generated Higher Quality and Faster Turn Arounds

The Problem

GreensGroomer WorldWide, Inc started in 1996 selling one product using a fabrication company located 40 minutes from the GreensGroomer assembly shop. While the fabricator produced acceptable finished products (frame, wheel lift, drawbar, and other misc. parts), we needed better weldments and closer tolerances, plus the ability to make changes on short notice.


The History of Metal Fabrication

Visit any natural history museum and you’ll see that metals have had an important role in human civilizations for thousands of years. Initially admired for its rarity and beauty, metal was used as decoration, a symbol of elite status in many ancient societies. As people learned more about them and discovered ways to mine and refine ores, metals became the foundation for the bustling, global economy we’re familiar with today. (more…)

Company Culture: Creating an Identity

Every company, no matter what industry or business type they participate in, has a culture that helps create and support their identity. This culture impacts everything that happens day-to-day. It is its own living, growing thing. Company culture will evolve as business grows and changes. It’s the responsibility of your company’s management team to establish and protect it, and test the alignment with organizational goals. The management team has to play offense and defense constantly to make sure company culture is protected and aligns with your core values. Taking an active role developing culture is a good way to create a company that not only produces top-quality products, but is also a good, quality place to work.


Sheet Metal Fabrication With Stainless Steel Alloys

Steel, in general, is iron alloyed to carbon. Sometimes, other elements are added to create different kinds of steel, which do different things. Inox steel, more commonly known as stainless steel, is a steel alloy and is a common material used in manufacturing. It’s popular because it doesn’t easily stain, corrode, or rust. These alloys can be found in a number of different varieties. Two very common types are 304 and 316 stainless steel alloy. These two different types of stainless steel can be used for a number of different applications and are what many sheet metal manufacturers choose to use. While these two alloys have some similarities, they ultimately have different components and characteristics.  (more…)

Sheet Metal Fabrication With Aluminum Alloys

Aluminum alloys are extremely popular for manufacturing parts and components since they have a wide range of characteristics, they’re lightweight, resistant to corrosion, have a high electrical conductivity, and can be shaped into almost any form. Aluminum is widely used and readily available, but not all aluminums are the same. Different aluminums have different characteristics that will determine if it’s a suitable choice for a project. While there are several different kinds of aluminum out there, all with different characteristics, here at Mainstay we consistently use two different kinds of aluminum sheet metal material for our metal fabrication jobs.  (more…)