Hurricane Sandy Reconstruction Building Up Homes, Businesses and the Economy

Hurricane Sandy wreaked havoc on the American northeast in late October of last year. Residents and business owners in New Jersey and New York City, along with Long Island and parts of the Mid-Atlantic felt the harsh effects of the 2012 superstorm. Since the horrific event reconstruction efforts have restored homes, businesses and even the economy.

Just days after the storm, reports surfaced from the Associated Press that reconstruction projects were going to play a role in rebuilding the American economy. The storm caused an estimated $50 billion in damages to personal property and businesses, along with added living costs. Over the months since the storm, construction increases in affected areas have been attributed to Hurricane Sandy.

The construction isn’t just a means of rebuilding what used to stand along the coastlines. State officials are hoping to build floodplains and other protective measures to keep this kind of storm from destroying homes and businesses in the future. New Jersey is in the process of spending $300 million to purchase homes in flood-prone areas, with New York spending $197 million to do the same, according to the New York Times.

Home and business owners are still facing obstacles in rebuilding their property hit by Hurricane Sandy. “The state is telling us that the funding from the federal government simply has not been as quickly forthcoming as it needs to be,” New Jersey Newsroom reports Assemblyman Gary Schaer said. “The federal government is pointing its fingers back at the state.” This follows the Federal Emergency Management Agency (FEMA) approving $1.4 billion in assistance as of June 3.

With work left to be done in states like New York and New Jersey, there is an influx of jobs for people in the construction industry. As different areas get grants, with $1.9 being given to Longport, N.J. as recent as late July, more job opportunities will be available for construction workers. Though this work is in the wake of tragedy, it has provided an opportunity to boost the economy.

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The Evolution of China – Part 2: Quality in Manufacturing

In our last blog post we talked about China’s growing middle class, and the hurried pace of unocupied appartmentsnew construction to keep up with the influx of people and automobiles in Chinese cities. This unbridled growth paints a familiar picture, both to America in the early part of the 20th century, and to Japan decades later in the 60s, 70s and early 80s.

Anyone familiar with the American Industrial Revolution knows that growth happened first, and only later did regulations governing quality, safety and both general and industrial pollution come into effect. Japan too, experienced a similar era of growing pains. After World War II, there was a need throughout the country to rebuild. New residential and commercial buildings needed to be erected, and generations of people needed employment. In a short period of time, market and constructionJapan began rebuilding their infrastructure, and strengthening their manufacturing base with new machines and new workers.

At first, the large majority of Japanese manufacturing output was relegated to small plastic products. These products gained a reputation for both their cheap cost, and their cheap construction. Soon, Japanese manufacturers moved on to products like automobiles and motorcycles. These too entered the global marketplace at very low prices, and were characterized by consistent quality issues. The low prices on Japanese goods were due in large part to the low wages paid to Japanese workers.

But then a change came. Even with their quality issues, Japanese automobiles and bicycles proved to be major competition for American and European built products as a result of their low prices. As sales strengthened, Japanese manufacturers were able to gradually improve quality. At the same time, wages began to improve for Japanese workers, and the prices of made in Japan products began to increase. But with a laser focus on efficiency, commercial building (1)Japanese manufacturers were able to keep prices competitive even as the standard of living increased throughout the country. Things progressed to such a point that Japanese products became and are still known for their high quality.

Des predicts a similar metamorphosis for China. At most of the facilities he visited, he found that hourly wages had nearly doubled in recent years, and that salaried employees had likewise seen substantial increases in pay. At the same time, Chinese made products have increased greatly in quality, which is what makes so many Chinese manufacturers trusted partners for Deeco Metals.

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The Evolution of China – Part 1: A Growing Middle Class

Recently, our president Des Sinclair traveled to China to inspect the facilities of potential Construction commercialDeeco Metals manufacturers (for more information on this vetting process, read our “Vetting Our Manufacturers” blog post). While he was there, he made some keen observations about the country. There’s a lot of talk about the role Chinese manufacturing plays in the global market, but not much talk about the country itself. We’d like to share Des’ observations with you in the hopes of painting a clearer picture.

China is a country that’s growing, and growing fast—sometimes at a rate that outpaces the country’s ability to keep up with that growth. Since Des’ last visit, the number of commuters on bicycles has greatly declined, with a corresponding increase in automobile usage. This is due in large part to a growing middle class. As more and more citizens start their own businesses with local government assistance and subsidies, both the middle class and the wealthy grow in numbers. Right now, this abundance of automobiles has resulted in frenetic driving practices, but everyone seems to have adjusted to the frenzy and no one Constrution Residencegets angry—a practice Des has coined “passive aggressive driving.”

Drivers also face challenges from less than ideal roadways, a symptom of a larger infrastructure issue. As the population moves into the cities, the hurried construction of roads and buildings has resulted in many cases in less than ideal construction quality. In addition to rough roads, numerous buildings showed foundational cracks and flaking plaster. Commercial and residential construction is actually outpacing the rate at which owners can find occupants for their buildings, leading the government to contemplate instituting a tax on these owners to curb the rate of construction large buildingconstruction. As is well documented in the media, pollution continues to be a pressing issue as well.

All of this growth, while hurried, is building towards an impressive future. Check back in a couple of weeks for Part 2 of our series, where we talk about the changes affecting Chinese manufacturing, and Des’ prediction on where China is heading.

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Lean Manufacturing – Cutting Costs with a Tiered Supply Chain

Lean manufacturing is a simple concept: eliminate waste, cut costs and increase your bottom line. While the concept is simple, there are many ways to execute the process. One strategy is to make use of qualified suppliers, who in turn, make use of other suppliers until a tiered supply chain is born.

A great example of this system at work can be found in the automotive industry. In the past, car manufacturers would manufacture most every component and then assemble each car. To facilitate this process, they maintained an inventory of hundreds of thousands of parts. Today, those parts are distributed amongst several suppliers, each of whom maintains their own inventories.

A Tier 1 supplier provides complete systems and assemblies directly to the car manufacturer. A tier 2 supplier provides parts and components to the Tier 1 supplier. For example, a tier 1 supplier may provide a complete braking system to a car manufacturer, while a tier 2 supplier would supply the tier 1 company with brake components used on the final brake system.

This provides many cost saving advantages to manufacturers. Warehousing fees are eliminated because no inventory is kept. Cash flow is not greatly impacted since parts are paid for only when they’re delivered and parts are delivered only when they’re needed. Utilizing a tiered supply chain also provides a quicker turnaround of finished products, as well as a safety cushion in cases of spikes in demand. If an unexpectedly large order comes in, material is readily available and is only a phone call away from your tier 2 suppliers. As soon as the urgent demand is filled, these suppliers immediately start manufacturing parts to replenish their inventory, thereby restocking your parts cushion.

Lastly, this system allows manufacturers to take advantage of economies of scale. Instead of placing separate orders each day or each week, manufacturers will place six or twelve month orders that are then kept in supplier inventories. These large order volumes result in lower costs for all parties while strengthening the tier 1 manufacturer’s bottom line.

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Vetting Our Manufacturers

Deeco Metals prides itself on working with some of the best manufacturers in the world. How do we know they’re the best? We personally inspect their facilities to ensure that they meet our stringent requirements. Unlike many in our line of work, we don’t work with just anyone. All of our manufacturers are audited on a yearly basis to ensure that our customers are getting products of only the highest quality.

The process of finding manufacturers begins with having an engineer in the country that the mill is located in. Having someone local is important, because they can provide personal insight on mills that other searches simply can’t provide. It also helps to have someone who speaks the local language. Our on-site engineer reviews companies that we direct him to as well as recommends companies that fit our criteria. Once it is decided that a mill might suit our requirements, he arranges a trip to visit and inspect the plant.  At the same time, he may visit other existing suppliers in the area that might be of value.  At the time of his visit and after meeting everyone of importance, he spends time with the engineering & quality group to inspect their production and quality systems.  If he is satisfied that the plant can provide good quality parts, he forwards his approval to our President Desmond Sinclair.

Upon review of our engineer’s comments, Des will arrange a trip to that area to visit the newly recommended suppliers as well as our existing suppliers. Only after his review will he give his stamp of approval.  Des comes from a manufacturing and engineering background, so he’s familiar with what it takes to be a top quality manufacturer. From the quality of the machining equipment to the overall manufacturing process, he inspects the entirety of the plant to ensure it will fulfill our customers’ order requirements.

In some instances, our customers want and need to visit and inspect our plants. In most situations like this, Des has gone with the client to inspect the plant that will supply them or that already supplies them. In some cases, clients have gone on their own to inspect the mills. Other times, due to company policies, they’ve hired third party companies to do the inspection.  If this is your company policy, we can recommend some excellent third party inspection companies.

Once a company has reviewed our offering and determined that we would be a good fit, our clients send us a purchase order for the required material. It is most common that at the start of every project, the manufacturer has to construct new tools and dies to produce the desired component.  Our standard practice is to provide first article samples along with our supplier’s dimensional reports. Upon receipt of our sample and reports, our clients then perform their own dimensional inspections and material analyses on the sample and determine whether or not to approve the FAS (First Article Sample) to release the full production order. There is a 50% charge to our clients upfront for the tooling, followed by the remaining 50% once the first article sample is approved. If there is a problem with quality on the first article sample that cannot be rectified, our clients receive their initial 50% back.

From lean practices to top-of-the-line equipment, there are many theories on what it takes to be successful in manufacturing. In our experience, we’ve found trust and a good relationship to be the most vital components of success. That’s why we personally inspect each manufacturing plant. That’s why we allow our customers to do their own inspection. And that’s why we offer our first article approval process with a no risk refund. There’s nothing more important than knowing that your project is in good hands.

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Dealing with the Unexpected

It’s our job to make sure that our customers’ projects go smoothly. That means managing complications with manufacturers before they ever become problems for our customers. To be successful at managing the unexpected is a two-fold process. First, we make sure to always maintain a wide base of manufacturers. Having plenty of trusted plants on hand keeps us from ever having too many eggs in one basket. Second, we keep our eye on world events, always watching the political arena and keeping track of exchange rates.

In the end, it all comes down to foresight and flexibility. Once we had an Australian manufacturer producing special custom metal products for an architectural customer of ours. The Australian manufacturer began having financial problems and was purchased by another group. That group did not want to continue with the parts we were supplying, so we found two plants that could manufacturer the same type of product, one in Spain and one in Italy. We moved the tooling to these plants without our customer ever being affected. Then, when the Euro Dollar was introduced, the prices in Spain and Italy skyrocketed.  Before this affected our customer, we located a plant in Korea and moved all our production there. There were no hiccups with delivery, service or quality. It was a seamless transition, and we were able to maintain the price the customer had been paying.

Consistency is important in any industry, and manufacturing is no different. Being able to stick to consistent production and cost schedules is essential to long term success. At Deeco we make it a priority to maintain that consistency for our customers.

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Metal Engineering Experts

When we get an inquiry from a customer, we don’t simply hand it to one of our manufacturers and return with a quote. We take a look at the design of the part, and if it’s presently being manufactured we take a look at how. We have a great deal of experience with metal and metal manufacturing. We use this experience to engineer the part in all aspects. Our goal is to make parts lighter, and manufacturing cheaper without any sacrifice in structural integrity.

Often, we receive designs from engineers who have recently graduated. Many times they design products according to textbook standards, giving each part a machined surface. There are some software programs that use this as a default setting as well. We’ve found that in many cases a cast surface will work, and will save money on manufacturing. We also get inquiries with outdated material specifications. By recommending a substitute alloy with the same (or better) properties, we’ve been able to save customers 30 and 40% on materials.

These are just some examples of how we’ve been able to take a design and make it better. Times are challenging right now. Everyone’s looking to save money where they can. At Deeco Metals, we have the skill to cut costs without cutting quality.

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