Ask any engineer what separates a “pretty good” part from a great one, and you’ll hear the same answer: process. Achieving tight tolerances once is an accomplishment; doing it repeatably, on schedule, at scale, across varying geometries and materials, comes down to disciplined improvement. At Hammond Machine Works, continuous improvement isn’t a project with a finish line. It’s how we approach CNC machining, fabrication, welding, and laser cutting every day, so our customers receive parts that fit, function, and last.
Why improvement—not slogans—wins
There’s a real business case for refining how parts get made. Industry analyses consistently show that the cost of poor quality (COPQ), including scrap, rework, returns, and lost production time, can consume 10–20% of total revenue in manufacturing operations. Reducing those losses drops directly to the bottom line, which is why ongoing quality improvement is not optional for manufacturers who care about their customers’ competitiveness.¹
Downtime is another hidden cost. Across manufacturing, the average unplanned downtime event costs about $125,000 per hour, according to Aberdeen Group and IndustryWeek research. In high-volume industrial environments, those losses can reach millions per hour. The point is clear: improving process stability and equipment reliability is one of the most powerful ways to protect customer schedules and budgets.²
Even overall equipment effectiveness (OEE) data shows the opportunity. While world-class OEE performance approaches 85%, many discrete manufacturers operate closer to 60–75%. Every percentage point gained through smarter process control, improved tooling, and better scheduling translates into faster turnaround and more predictable lead times.³
What continuous improvement looks like in parts manufacturing
For precision parts, the “how” matters as much as the “what.” Here are the types of incremental improvements that directly translate into better parts and smoother production:
1. CNC process optimization
Refining toolpaths, feeds and speeds, and workholding setups eliminates vibration, stabilizes surface finishes, and tightens dimensional control—especially on complex, multi-operation components. Continuous tuning also reduces cycle time variance, which improves schedule reliability without sacrificing tolerance.
2. Smarter inspection, earlier in the process
Integrating in-process checks, whether probing routines in CNC cells, fixture-based gauging in fabrication, or first-article verification on welded assemblies, shortens feedback loops. Catching drift early reduces scrap and rework before additional value is added, improving both efficiency and consistency.
3. Fabrication and welding repeatability
Laser-cut blanks with consistent edge quality and minimal heat-affected zones set downstream welding up for success. Standardized weld procedures, engineered fixtures, and consistent parameter settings reduce variation across shifts, which improves first-pass yield and reduces touch-up time.
4. Laser cutting for precision and throughput
Small process adjustments, like optimizing nesting layouts, lead-ins, and assist-gas parameters, can significantly improve both sheet utilization and cut quality. Those refinements minimize secondary operations and improve fit-up for assemblies later in the process.
5. Maintenance that prevents surprises
Predictive maintenance on spindles, drives, lasers, and compressors stabilizes capacity and prevents downtime. Given the cost profile of interruptions, even small improvements in maintenance planning compound into major uptime and delivery advantages.
6. Cross-functional problem solving
When machinists, programmers, quality techs, and welding leads work together using shared metrics, issues get solved at the source. Operator-driven improvement initiatives, whether to reduce setup time, improve tooling life, or refine part flow, drive measurable performance gains in low-volume, high-precision manufacturing environments.
How customers feel the difference
For OEMs and tier suppliers, the results of Hammond’s continuous improvement mindset are practical and measurable:
- Tighter, more consistent tolerances across CNC-machined and fabricated components.
- Reduced downtime and rework because parts arrive to spec and integrate seamlessly in assembly.
- Shorter, more reliable lead times through process predictability and streamlined workflows.
- Lower total cost of ownership thanks to reduced waste, longer tool life, and better material utilization.
Continuous improvement also builds resilience. Market demands shift, engineering revisions occur, and production volumes fluctuate. A manufacturing partner that continually refines its processes can adapt to those changes without compromising quality or delivery.
Metrics that matter
At Hammond, improvement isn’t abstract, it’s measured. Key metrics used to drive progress include:
- First-pass yield on CNC, fabrication, and welding operations
- Process capability (Cp/Cpk) for critical dimensions
- Setup and changeover time versus target benchmarks
- Material quality and supplier performance to ensure part integrity
- Equipment uptime and efficiency to maintain steady throughput and plan maintenance proactively
These aren’t just internal scorecards, they’re performance indicators our customers can see reflected in every part delivered. When yield increases, changeovers speed up, and downtime decreases, the benefits extend directly to production schedules, assembly reliability, and long-term value.
The bottom line
Precision isn’t static. It’s the result of hundreds of disciplined improvements across machining, fabrication, welding, and laser cutting, each one aimed at eliminating waste, controlling variation, and enhancing repeatability.
The data proves why it matters: quality issues can consume double-digit percentages of revenue, and downtime costs accumulate quickly. Continuous improvement protects customers from both, ensuring every Hammond part performs the same way, every time.
If your next project demands reliable precision and repeatable performance, partner with a manufacturer that never stops improving the process behind every part.
References
- American Society for Quality (ASQ), “The Cost of Poor Quality”
- IndustryWeek / Aberdeen Group, “The True Cost of Downtime in Manufacturing,” 2023
- Reliable Plant Magazine, “Understanding and Improving OEE Benchmarks,” 202