Waste is a reality in every custom sheet metal fabrication shop—scrap metal, poor processes, and even wasted time all add up. But what if there was a way to cut down on waste without cutting into your bottom line? The good news is that there is, and manufacturing consultancy services can help metal fabrication pros be productive with their materials and operations.
Table of Contents
- Why Waste Matters More Than You Think
- How to Find Waste in Your Metal Shop
- The Eight Wastes of Lean in Metal Shop
- How Manufacturing Consultants Help Keep Waste in Check
- Virginia’s Recycling Struggles – And How Manufacturers Can Help
Why Waste Matters More Than You Think
At first glance, excess metal scrap or a bit of wasted material might not seem like a big deal. But over time, that waste adds up. Here’s what unchecked waste could be costing your shop:
- Lost Profits – Every extra cut, discarded piece, or problematic workflow is money thrown away.
- Higher Costs – More waste means higher disposal fees and raw material costs.
- Inefficient Operations – Unnecessary steps in production slow down workflows and reduce productivity.
How to Find Waste in Your Metal Shop
Before you can eliminate waste, you have to see it. The longer you’ve worked in a system, the harder it is to recognize inefficiencies. This is where a waste walk comes in—a planned visit to your shop floor where you observe workflows and identify wasteful practices.
When conducting a waste walk, think about these three key prerequisites:
- Know what waste looks like – Use the eight wastes of lean manufacturing as your guide.
- Use a standard methodology – Document waste as you find it, using checklists or process maps.
- Have resources to act on waste findings – Identifying inefficiencies without implementing fixes is just another waste of time.
The Eight Wastes of Lean in Metal Shops
Lean manufacturing principles define eight common wastes that can drag down efficiency in precision sheet metal fabrication:
- Defects – Rework and scrap due to errors in production.
- Overproduction – Making more than is needed, leading to excess inventory.
- Waiting – Delays caused by shortages, approvals, or missing data.
- Non-utilized Talent – Skills and abilities of employees going unused.
- Transportation – Unnecessary movement of materials across the shop.
- Inventory – Excess raw materials or parts waiting to be processed.
- Motion – Wasted movement due to poor workstation layout or ergonomics.
- Excess Processing – Adding steps or features beyond what the customer values.
A simple way to evaluate any task is to apply this test:
- Customer Value-Adding (CVA) – Does this add value that a customer would pay for? If yes, keep it.
- Business Value-Adding (BVA) – Does this support operations but not directly add value? If yes, improve it.
- Non-Value-Adding (NVA) – If it’s pure waste, eliminate it.
How Manufacturing Consultants Help Keep Waste in Check
Advanced manufacturing consulting brings a fresh perspective to your operations. Experts analyze workflows, identify opportunities for improvement, and recommend solutions. Here are some of the ways they can help:
1. Optimizing Material Use
- Using nesting software to maximize sheet metal usage.
- Recommending CNC machine settings and CAD software that reduce scrap.
- Identifying ways to repurpose leftover materials instead of discarding them.
2. Streamlining Processes
- Analyzing your production flow to eliminate unnecessary steps.
- Reducing waiting time between processes.
- Improving machine maintenance schedules to prevent breakdowns and wasted material.
3. Implementing Recycling Programs
- Setting up metal scrap recycling to turn waste into profit.
- Managing coolant and lubricant recycling to reduce hazardous waste.
- Training employees on proper disposal and reuse of materials.
4. Reducing Energy Waste
- Upgrading to energy-efficient machinery.
- Implementing automated shut-off systems for idle equipment.
- Identifying ways to reuse heat or power generated by machines.
5. Training & Workforce Development
- Teaching employees best practices for waste reduction.
- Encouraging team participation in identifying wasteful processes.
- Establishing waste reduction goals and tracking progress.
Virginia’s Recycling Struggles – And How Manufacturers Can Help
Even if your metal fabrication services include recycling, Virginia’s declining recycling infrastructure may make it harder to sustainably manage waste. Here’s important points to know from state data:
- The number of core recycling facilities in Virginia has dropped by 13% since 2012.
- Only 8% of plastic bottles are recycled in the state—meaning that even some “recyclable” materials still end up in landfills.
- State agencies reported a dramatic drop in recycling, with total recycled material falling from 698 metric tons in 2023 to just 104 metric tons in 2024.
While bottle bills and extended producer responsibility laws have been discussed, Virginia lawmakers have yet to pass major waste management reforms. This means metal shops must take charge of their own waste reduction strategies or with the help of a manufacturing continuous improvement consultant rather than rely on public recycling programs.
Ready to Cut Down on Waste?
The reality is, waste in metal fabrication isn’t just about materials—it’s about time, energy, and money. With the right strategies, you can watch your business grow and thrive.
GENEDGE is hiring a Welding Training Supervisor in Norfolk! If you’re experienced in welding and passionate about workforce development, this role gives you the chance to lead training programs and help shape the future of welding education. Learn more and apply at GENEDGE Careers.
Need expert advice? A manufacturing consultant from GENEDGE could be what your shop needs.
