Led by Sean Derivan, Director of Manufacturing, the Total Metals Fabrication Team includes professional metal fabricators and machinists for the cutting, forming, and assembly of our architectural metal product lines; a shipping, receiving and inventory group; a purchasing and subcontractor management group; and a scheduling support group responsible for the development and maintenance of schedules for each project underway at Total Metals.
The Fabrication team occupies approximately 15,000 square feet of our Chandler facility. The team is organized in seven basic fabrication disciplines necessary for the manufacturer of our product lines; shearing and cutting operations; brake and folding operations; roll forming and bending operations; bench and specialties operations; ACM routing and assembly operations; welding and soldering operations; and painting and coating operations. Each of these disciplines is equipment with some of the latest state of the art capital equipment for their particular operation.
- Shearing and Cutting Operations: This operation is responsible for the cutting of the metal to be used for all products to the proper length and width prior to fabrication. Equipment includes a large 50- ton shear and vertical metal cutting saw as well as a number of smaller shears. Since most of our material arrives from various suppliers in coil form, the handling equipment necessary to move these large coils is available.
- Brake and Folding Operations: This operation is performed by large programmable machines capable of bending and forming the metal into products such as coping cap, reglet, gutters, and various angled metal trim and support pieces.
- Roll Forming and Bending Operations: The company has a number of roll formers that are mechanically or computer programmed to form panels with such features as standing seams in long roof panels and many other snap together features. Other machines in this discipline are used to fabricate radii in these long panels as they are being formed to be used in domes or arched features. Sometimes due to the length of the panels required, roll forming equipment and personnel are dispatched to the job site to roll panels on site.
- ACM Routing and Assembly Operations: Composite Materials are cut and routed on large computer programmed two dimensional milling machines. These machines are programmable to cut multiple pieces simultaneously out of large flat stock sheets provided to Total Metals by various vendors. This capability saves substantial time and reduction in material waste resulting in a considerable cost savings to our customers. Once the ACM is cut to its proper dimensions it goes to a bench assembly department for attachment of the hanger and support pieces prior to shipping to the job site.
- Bench and Specialty Operations: Certain fabrications in the department require hand formation and are assembled by highly skilled metal fabricators using rivets, solder, or sometimes welding techniques. Product lines such as collector boxes and downspouts are fabricated in this operation. This department is also responsible for a number of specialty items such as copper ascent features, decorative domes, and decorative metal items.
- Welding and Soldering Operations: Equipped with automatic soldering machines for the joining of copper items and MIG and TIG welders for assembly of metal support items. This department is also responsible for field and shop support items manufacturing.
- Painting and Coloring Operations: This department equipped with a certified paint booth is responsible for all painting operations done in the plant as well as the application of all pre-delivery coatings applied to some of our product lines. An example being that Total Metals can deliver “pre-aged or Patina” copper panels allowing the customer to receive from the factory his desired look without having to wait for the natural aging process to occur.
Equipped with an elaborate inventory support program, our Shipping, Receiving, and Inventory team members control the inflow of raw materials into our facility as well as the outflow of finished product to the field project locations.
Essential for proper accounting and cost control our purchasing and subcontractor management personnel can track the progress of their orders for input to our scheduling group as well as to our accounting for proper billings to the customer.
The final member of our Fabrication Team is our scheduling group. To properly utilize our resources with multiple independent projects on going simultaneously with different customers each with its own unique schedule, Total Metals employs a sophisticated computerized scheduling system. This scheduling system establishes a project schedule at the receipt of contract and is updated daily as the project schedule is impacted by weather, delays of other subcontractors, or sometimes by your project moving ahead faster than anticipated. This particular project schedule is then incorporated automatically with all other ongoing projects providing us a peak load analysis. This analysis is used in the long term for manpower and capital equipment plans. In the short term, this overall schedule becomes the controlling vehicle through the entire company. Bi-monthly senior management meetings are held to coordinate and establish priorities from this schedule. Our customers are kept abreast of our internal schedules when and if their project schedules change and conflicts arise in our potential ability to support their new schedule.