{"id":8915,"date":"2020-07-08T10:46:40","date_gmt":"2020-07-08T10:46:40","guid":{"rendered":"http:\/\/www.paulo.com\/?p=8915"},"modified":"2024-01-17T18:29:03","modified_gmt":"2024-01-17T18:29:03","slug":"reshoring-your-heat-treating-operations-an-overview","status":"publish","type":"resources","link":"https:\/\/www.paulo.com\/es\/resources\/operaciones-de-tratamiento-termico-una-vision-general\/","title":{"rendered":"La deslocalizaci\u00f3n de sus operaciones de tratamiento t\u00e9rmico: Una visi\u00f3n general"},"content":{"rendered":"<p><span style=\"font-weight: 400;\">The coronavirus pandemic has many manufacturers rethinking their supply chains. After enjoying years of cost-savings from offshore operations and practices such as just-in-time inventory, manufacturers are seeing their previously smooth-running production and transportation operations grind to a halt.<\/span><br \/>\n<span style=\"font-weight: 400;\">The mounting expense of stalled operations has spurred manufacturers to move quickly to reshore or localize production functions, including heat treatment.<\/span><br \/>\n<span style=\"font-weight: 400;\">Companies recognize that the risks and strategic impacts associated with offshore manufacturing simply outweigh the shrinking wage advantages found in emerging markets.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">There are no easy fixes. But there are best practices and workarounds you can implement to\u00a0 successfully reshore your manufacturing to the U.S. &#8212; including your heat treatment operations.<\/span><br \/>\n<span style=\"font-weight: 400;\">In this article, you\u2019ll learn what to expect and how to initiate reshoring your operations.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">You\u2019ll find helpful discussions about:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\"><b>Understanding why manufacturers<\/b><span style=\"font-weight: 400;\"> are shortening their supply chains<\/span><\/li>\n<li style=\"font-weight: 400;\"><b>Recognizing common challenges<\/b><span style=\"font-weight: 400;\"> of reshoring or localizing heat treating operations<\/span><\/li>\n<li style=\"font-weight: 400;\"><b>Filling knowledge gaps<\/b><span style=\"font-weight: 400;\"> created by moving from one heat treatment supplier to another<\/span><\/li>\n<li style=\"font-weight: 400;\"><b>Maximizing the opportunity presented<\/b><span style=\"font-weight: 400;\"> by reshoring heat treatment operations<\/span><\/li>\n<\/ul>\n<p><a href=\"https:\/\/www.paulo.com\/contact-us\/\"><span style=\"font-weight: 400;\">Learn how Paulo can help with relocating your heat treating operations<\/span><\/a><\/p>\n<h2><span style=\"font-weight: 400;\">Why are manufacturers reshoring?<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Manufacturers are seeing the benefits of once again producing in the United States, the world\u2019s largest market. According to the Reshoring Initiative [<\/span><a href=\"http:\/\/www.reshorenow.org\"><span style=\"font-weight: 400;\">www.reshorenow.org<\/span><\/a><span style=\"font-weight: 400;\">], companies that reshore say their top reasons for moving back the U.S. include reduced lead time, higher product quality and consistency, the need for a skilled workforce, and the desire to strengthen the U.S. economy by creating productive jobs.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">Even as they manage their responses to the pandemic, manufacturers are looking ahead to what could be the next big disruption to global supply chains. Possibilities include border closings, tariffs, war, and shipping strikes.<\/span><br \/>\n<span style=\"font-weight: 400;\">To reduce the impact of these and other potential disruptions to their supply chains, m<\/span><span style=\"font-weight: 400;\">any domestic manufacturers are considering or have already decided to move their operations closer to home.\u00a0<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Common challenges and pitfalls<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Heat treating is a critical manufacturing step that must be done correctly for parts to perform. Clearly defined specifications and scientific certainty are essential for success. Manufacturers need to understand what to expect when relocating heat treating operations and what they can do to overcome challenges.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">Here are some common areas of concern.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Materials and processes<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Relocating operations changes more than the physical location of your heat treatment processes. When manufacturers relocate, they sometimes discover that their finished parts were being produced from a different material than they originally thought. Offshore partners may have substituted a different material because they may not have had access to the steel grades or specialty alloys more commonly available in the U.S.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">The same situation applies to the heat treatment specifications being used by offshore partners. Some manufacturers we\u2019ve worked with have found that adjustments were made to the processing of their parts varying from the original specifications, sometimes as a result of the substitution of alternative materials. To further complicate matters, these adjustments may not have been documented by the former supplier.<\/span><br \/>\n<span style=\"font-weight: 400;\">Both, and especially a combination of, these unexpected discoveries can cause major headaches for manufacturers when they take over production. If heat treatment specifications are not exactly tailored to the parts\u2019 material, it can lead to costly ramifications such as scrap parts, lead-time delays, and even potential recalls should the parts enter the supply chain.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Testing practices<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Overseas, testing practices often differ from those used domestically. Reasons for these differences include availability of testing equipment and cultural preferences regarding testing methodology and measurement. For example, manufacturers in Japan commonly read case depth from the core of the part outward, where in the U.S., <\/span><a href=\"https:\/\/www.paulo.com\/understanding-effective-vs-total-case-depth\/\"><span style=\"font-weight: 400;\">case depth<\/span><\/a><span style=\"font-weight: 400;\"> is read starting at the surface of the part and progressing toward the core. In addition, offshore suppliers may have different preferences for testing locations on your parts.<\/span><br \/>\n<span style=\"font-weight: 400;\">Occasionally, manufacturers who have relocated also find that documentation of testing procedures may not meet their expectations. No matter the discrepancy, establishing proper testing methods once domestic production begins can consume valuable time and resources, impacting the ability to deliver parts on time with scientific certainty in the results.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Institutional knowledge<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">You can expect to lose some level of detail in records or procedures in the transmission of specifications and procedures. Think of the recipe for your grandma\u2019s cheesecake. Who knew she added another half teaspoon of vanilla? Some production steps may have been added, altered, or passed over by teams overseas.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">For example, your previous partner may have noticed that a slight increase in time in the vacuum furnace yielded better hardness results, but may not have taken the steps to have the heat treating specifications officially updated to reflect the change\u2014instead, the teams processing your parts communicated it by word of mouth. This lack of documentation (also oftentimes coupled with a language barrier) can leave this important information lost in the relocation process.<\/span><br \/>\n<span style=\"font-weight: 400;\">While a missing dash of vanilla won\u2019t hurt anyone when it comes to cheesecake, in heat treatment, adjustments to time, temperature, and atmosphere chemistry (to name a few) are both business- and safety-critical.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">How to fill in knowledge gaps once you\u2019ve relocated<\/span><\/h2>\n<h3><span style=\"font-weight: 400;\">Reverse engineering<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">One of the most effective ways to uncover knowledge gaps is to reverse engineer a process\u2014start at the end of a procedure or a completed product and work backwards.<\/span><br \/>\n<span style=\"font-weight: 400;\">At Paulo, our metallurgy team will use a spectrometer to determine a specific material, which may not be what you\u2019ve been told it is or what you believe it to be. We can then determine what likely heat treatment was used by conducting tests on hardness, case depth, and microstructure.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">With the largest in-house metallurgy team of any commercial heat treater, Paulo draws on decades of experience (and process modeling tools built on that experience) when approaching reverse engineering. Our deep expertise allows us to reach accurate conclusions faster, so you can get back to producing your parts.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Familiarity with differing global practices<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">One of the major challenges of relocating operations is not knowing what you don\u2019t know.<\/span><br \/>\n<span style=\"font-weight: 400;\">The more familiar you are with the procedures and regulations surrounding your offshore production, the more easily and more accurately you\u2019ll be able to replicate or adapt those practices in your domestic production.\u00a0<\/span><br \/>\n<span style=\"font-weight: 400;\">This process is completed far more quickly &#8212; and economically &#8212; when the team managing your relocation already knows how things are done in specific foreign markets and what needs to be done to adapt them for the U.S. market. At Paulo, our team is well-versed in manufacturing and quality control practices used in places such as China, Japan, Germany, and beyond.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Leverage relocation challenges for improvement<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">While investigating and solving these common challenges can consume both time and financial resources, the flip side is that it presents opportunities for improvement. Here are just two examples of how manufacturers like you can convert reshoring challenges into better results.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Material selection<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">It may have been years or even decades since you last evaluated your choice in materials for your parts. Reshoring presents an opportunity to re-examine material options and select the particular steel grade or alloy that best fits the needs of your application. You may wind up with better quality, longer lasting, and in some cases, <\/span><a href=\"https:\/\/www.paulo.com\/enhanced-property-treatments-ordinary-alloys-punch-above-their-weight\/\"><span style=\"font-weight: 400;\">more cost effective<\/span><\/a><span style=\"font-weight: 400;\"> parts as a result.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Specifications and testing procedures<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">By reshoring, your team can more easily set and enforce standards across your entire manufacturing operation, including heat treatment and part testing. By establishing appropriate standards, you\u2019ll gain peace of mind knowing that your parts will enter the supply chain fit for service in your application.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">How Paulo sets up reshoring efforts for a successful transition<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The experience of Paulo\u2019s metallurgy team lays the groundwork for a successful transition to a more localized approach. Our familiarity with operations previously conducted in places like China, Japan, and Germany provides you with an understanding of how to best collect data, answer questions and manage your reshoring efforts with greater speed and efficiency.<\/span><br \/>\n<span style=\"font-weight: 400;\">Our ability to help manufacturers with the transition of their heat treating is another example of Paulo\u2019s rock-solid foundation called <\/span><b><a href=\"https:\/\/www.paulo.com\/datagineering-at-work-the-paulo-advantage-paulo\/\">datagineering<\/a>. <\/b><span style=\"font-weight: 400;\">Datagineering brings together the very best of people, science, data, and technology to produce unparalleled results in thermal processing. It&#8217;s a concept that captures the work of our smart operators, engineers, metallurgists, and leaders at all levels throughout our entire system.<\/span><br \/>\n<span style=\"font-weight: 400;\">If you\u2019re considering localizing your manufacturing operations, or if you\u2019ve recently reshored, Paulo can help you manage the transition. Contact a Paulo expert to get started today on converting your reshoring challenges into higher quality and better efficiency.<\/span><br \/>\n<a href=\"https:\/\/www.paulo.com\/contact-us\/\"><span style=\"font-weight: 400;\">Learn how Paulo can help with relocating your heat treating operations<\/span><\/a><\/p>\n\n<section id=\"block_d77d3c344c60d18f55f342a57d0afb11\"\nclass=\"resources-related-sidebar\">\n        <div class=\"tax-container\">\n                            <strong>Markets<\/strong>\n                <ul>\n                                                                    <li>\n                                                            <a href=\"https:\/\/www.paulo.com\/es\/markets\/automovil-camion-pesado\/\">Automotive<\/a>\n                                                    <\/li>\n                                    <\/ul>\n                            <strong>Processes<\/strong>\n                <ul>\n                                                                    <li>\n                                                            <span>Heat Treating<\/span>\n                                                    <\/li>\n                                    <\/ul>\n                    <\/div>\n<\/section>","protected":false},"excerpt":{"rendered":"<p>La pandemia de coronavirus ha hecho que muchos fabricantes se replanteen sus cadenas de suministro. Despu\u00e9s de disfrutar durante a\u00f1os de ahorros de costes gracias a las operaciones en el extranjero y a pr\u00e1cticas como el inventario justo a tiempo, los fabricantes est\u00e1n viendo c\u00f3mo sus operaciones de producci\u00f3n y transporte, que antes funcionaban sin problemas, se paralizan. Los crecientes gastos derivados de la paralizaci\u00f3n de las operaciones han impulsado a los fabricantes a actuar con rapidez para deslocalizar o localizar la producci\u00f3n ... <a href=\"https:\/\/www.paulo.com\/es\/resources\/operaciones-de-tratamiento-termico-una-vision-general\/\">Contin\u00faa<\/a><\/p>","protected":false},"author":3,"featured_media":8929,"parent":0,"menu_order":0,"comment_status":"open","ping_status":"closed","template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"markets":[83],"processes":[92],"equipment":[],"methods":[],"materials":[],"parts":[],"resource-types":[195],"class_list":["post-8915","resources","type-resources","status-publish","format-standard","has-post-thumbnail","hentry","markets-automotive","processes-heat-treating"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.9 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Reducing pandemic impact on supply chains by reshoring 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