Levy’s features on the cover of Modern Machine Shop magazine
The March 2021 edition of Modern Machine Shop focuses on Levy’s Machine Works continuous improvement culture, methodology and process.
To read about some of the recent projects and focus on continually striving to improve that have helped make the company what it is today click on the below link:
https://modernmachineshop.mydigitalpublication.com/publication/?m=59264&i=694354&p=80
Levy’s Celebrates 40 Years
It was in August 40 years ago in 1980 that Calgary-based Levy’s Machine Works was founded by two machinists intent on making a contribution to the oil sector, which was then booming following the 1979 oil crisis driving output down and prices higher the year before.
It was only shortly after, however, that Levy’s originators found themselves having to get creative with generating income through any means of work, following the introduction of the tough and rigid national energy program (NEP) by then Canadian Prime Minister Pierre Elliott Trudeau, which slapped additional taxes on oil.
Since then and over its 40-year history Levy’s has had to withstand its fair share of ups and downs as the industry went through periodic downturn. Each time, however, the business endured and emerged from each challenge wiser and stronger. It’s fair to say that the ability to cope with adversity and make good decisions around changing situations has become one of the cornerstones of Levy’s success – the others being it’s reputation for quality, customer service and generally being able to get the job done.
Four decades on and the business finds itself navigating its way through a new and very different crisis: That of a global pandemic, not to mention its negative impact on industry and the economy in general. But, as always, Levy’s continues to push on through, remaining operational, providing the same high-end machining service and fulfilling customer needs.
If you have a requirement for precision machined parts then Levy’s Machine Works is happy to help. Please contact either 403 279 2010 or info@levysmachineworks.com.
Business Development Manager wanted
Levy’s Machine Works Ltd. is looking for an experienced and highly motivated Business Development Manager to drive new business and contribute to further growth. If you have a strong background in component machining, manufacturing or engineering, and previous experience in technical sales and generating new business, we’d like to hear from you. Please send a cover letter and resume to Richard Burton – General Manager: richard.burton@levysmachineworks.com
Larger Turning Capacity
Levy’s recently increased it’s turning capacity with the addition of a Mazak Slant Turn 550 machining center.
With a through spindle bore diameter of 10.5 inches” and a programmable steady rest, this powerful, high torque, heavy duty addition allows parts up to 36 inches in diameter and 120 inches long to be machined.
Moreover, the 45kw (30min/rating) spindle power and 7000 Nm of torque helps optimize machining times, particularly roughing.
If you have a requirement for large parts turning please don’t hesitate to call Levy’s. (Phone 403 279 2010 or e-mail: info@levysmachineworks.com)
The Benefits of Involvement – Employee-administered mini-audits
Getting all employees to buy into and develop the same level of knowledge and understanding of a company-wide system, process or initiative is a challenge at the best of times, no matter how conscientious and dedicated they may be.
Nonetheless, it is absolutely essential to ensure that a system is being used properly to fully serve its purpose and that all processes and procedures are continually evaluated and improved. This applies without exception to a business’s quality management system (QMS).
But how do you regularly evaluate without slowing the process or incurring many hours of downtime – time and cost which can smaller business in particular can often ill-afford? Training during implementation usually ensures that processes are followed and correct documentation completed at the outset but over time steps may be inadvertently missed or corners cut. Dedicated staff overseeing proper use, monitoring and correction may address this but is often another overhead smaller businesses can’t justify. Alternatively, bi-annual or even annual audits will identify and correct any issues but by the time this happens any accumulation of neglect or misuse can result in a whole whack of additional work to get things back on track.
One answer is mini-audits. Not full audits conducted every few months by a specific manager or quality lead, however, but impromptu, on-the-spot checks carried out at least monthly …and by employees chosen at random, regardless of their role. Why? As Benjamin Franklin said: “Tellme and I forget, teach me and I may remember, involve me and I learn.”
Indeed, the benefit of getting more employees involved includes each individual gaining personal knowledge through first-hand experience of the processes, regardless of whether they use them regularly or not. This in turn provides them with a better insight into how all processes and procedures interrelate and interact within the company-wide system, as well as an appreciation of how the business operates overall. Furthermore, it helps them to become more engaged and comfortable with taking on a bit more responsibility. And, with regard to cost to the business, this is relatively insignificant as these mini-audits can generally be completed within an hour or less.
Calgary-based precision machining business Levy’s Machine Works began to conduct employee administered mini-audits recently, following its implementation of a new quality management system and successfully obtained ISO 9001:2008 certification in 2015.
As a QMS had been in place at Levy’s for many years prior to obtaining the certification most employees were already reasonably used to working with processes such as part inspections, non-conformance reporting, formal job routings and shipping/receiving procedures. That said, more stringent processes and procedures were developed to meet the standard, which in turn meant further instruction on how they worked and were to be followed. How and why the QMS needed to meet the ISO standard was also a focus as was its importance to the business overall.
Once in place it was obvious that the QMS and the way in which employees worked within it needed to be continually evaluated and maintained to remain effective. So, the objective of the employee-administered mini-audits was to keep the business ‘fighting fit’ in terms of being able to pass the most stringent of external audits or customer inspections at any time.
One key benefit of having different employees involved as opposed to just, say, the quality lead is that a fresh pair of eyes is often more likely to see problems that the same pair of eyes may miss. It also helps provide a more ‘level playing field’ in terms of everyone audited and everyone being scrutinized, rather than one person doing the policing and everyone else being policed. In fact, with everyone having the chance to audit as well as be audited a it also creates an opportunity for some healthy competition, with the auditors keen to find room for improvement while the auditees not wanting to be picked up on doing anything less than a thorough job.
To properly get the employees’ ‘buy in’ though the task had to be made as easy and not at all daunting, particularly as it involved auditing processes with which they were otherwise unfamiliar. So, information from the initial QMS training presentation on the processes in use and the types of things to remember were used to create a checklist that would verify that processes were being followed, documentation completed and records kept. Simple questions were written alongside each of the ‘fail’/’pass’ checkboxes so that even the most laymen auditors could question those using process within each functional area. Ultimately this enables the auditor to determine whether the process was being followed and allows them to see first-hand how that aspect of a process worked as the auditee must provide an example of correct use.
Prior to each mini-audit the selected employee is fully briefed on what to do and why it is important. In addition to the checklist and a clipboard, mini-auditors are also given the ‘Auditor’ hard hat and badge so everyone can see that they have been tasked with conducting a mini-audit audit and therefore provide them with the responses and information they require. However, no advance warning is given to other employees as these inspections have to be impromptu to properly assess what is being done in the everyday situation. Also, every area, every process and every employee is subject to scrutiny, from the production staff and shop floor through to the management and main offices.
Like any initiative that may involve employees working outside of their core area (or comfort zone) there was the risk that many may be reluctant to take part and half-hearted execution would provide only mixed results but Levy’s experience with the mini-audits so far has been extremely positive. Each employee chosen to undertake an audit has thoroughly enjoyed the experience, with any initial reluctance turning to enthusiasm as they gained a better insight and understanding of how each of the QMS processes interrelate and interact. Improved understanding and appreciation for how the business operates seems to have made them a more integral part of the business as a result, their viewed responsibility now extending beyond just their ‘job. Moreover, the mini-audits serve their purpose with resounding success, with occasional missed steps or incomplete documentation being identified and reminders issued to prevent further occurrences.
In conclusion, the quality management system at Levy’s and all of its processes and procedures will remain in great shape because of its employees and their regular checks. Also, every employee having conducted a mini-audit goes on to make it their business to ensure they properly follow the processes and complete documentation going forward ….even if it’s just to make life a little harder for the next mini-auditor!
Levy’s Receives International Quality Standard Certification
As part of an ongoing commitment to quality and the continual improvement of its service to its customers Levy’s Machine Works Ltd. is pleased to announce that it has successfully met all the criteria for registration to the international standard ISO9001:2008.
Moreover, successful completion of the implementation process and both Stage 1 and Stage 2 certification audits was completed months ahead of the original schedule with only positive observations and zero non-conformances or noted opportunities for improvement. This is testament to the already robust quality management system in place at Levy’s as well as the efforts of all employees at the company who have made customer requirements an absolute priority in terms of quality and delivery over the past few decades.
This milestone in Levy’s successful 35 year history will ensure the continued focus on internal performance, overall quality and customer satisfaction, and is key to providing customers with a precision machining and manufacturing service that is second to none for many years to come.
To view Levy’s ISO9001:2008 certificate click: Levy’s ISO90012008 cert
To find out more about what Levy’s Machine Works Ltd. can do for you go to www.levysmachineworks.com or watch the short video at https://www.youtube.com/watch?v=6ZrAqmnrJ7o
Going Above and Beyond Just Price
When considering a machine shop to manufacture your components, price isn’t by far the only thing when it comes to properly fullfilling your needs.
There are machine shops and there are machine shops. You have a part you need manufactured so where do you go? Sure, you are looking for a shop that can offer you a competitive price but it’s critical to not overlook the importance of quality, delivery and most importantly overall cost. Indeed, a seemingly low price per part could even mean that potential issues with quality and delvery will end up costing you more.
Therefore, before making any decisions, you have to look at a machining business as a whole – that means its financial stability, it’s manufacturing and quality system, machining technology, skills and experience and, ultimately, what it can really do for you in going above and beyond in meeting your requirement.
First and foremost it’s important to put your trust in a business that represents little risk in terms of financial stability. The sound financial judgement that make a business stable is generally representative of good business and operational decisions all round. Shops that price low to win work can potentially compromise the customer and tend to think short-term. Those that price work realistically based on their skills and experience, and aren’t occasionally afraid to turn down work in the best interest of the prospective customer, demonstrate business integrity and strong potential for longer-term partnerships.
With regard to a machine shop’s manufacturing and quality system, this is essentially the end-to-end process of taking a customer requirement and raw material and turning it into something that will make the customer money. This includes everything from sourcing, engineering, programming, machining, inspection and shipping. Everything has to work seamlessly and provide value at every stage. Having proper, robust processes in place means the manufacturing of parts is both optimized and quality assured. Subsequently, the benefits flow through to the end-customer. Machine shops that are prepared to show you their operation, work with you on engineering and manufacturing methodology, and that have a well defined quality policy and objectives represent a solid prospective partner for your manufacturing needs.
The cornerstone of every machine shop, of course, is its machining technology. However, this can vary considerably from older, poorly maintained machines that lack the up-to-date features required to achieve high quality and cost-effective production, through to regularly maintained advanced manufacturing technology that can provide fast turnaround and high precision. It may be true that such technology comes at a cost and you would expect this alone to price more sophisticated shops out of the running but the reality is that such machine tools ultimately offer greater efficiency – not to mention reliability.
Also at the heart of any business is its people and nowhere more than in a machine shop are skills and experience directly responsible in representing value for the customer. Particularly in precision machining, only fully skilled, qualified and experienced machinists are able to provide the engineering expertise and level of quality required. In short, highly complex, close toleranced parts in exotic materials are seldom the forte of semi-skilled machinists or operators. So, if you are looking for precision machining of high value parts or input into the most effective and efficient production processes you need to ask a few questions about the skill level and experience on offer.
Lastly, and probably most importantly, is attitude. Attitude toward you and your requirement as the customer is vital in terms of attention to detail and properly understanding your needs. It also counts toward effective communication, which, in turn, is often the foundation of a good working relationship. Attitude of all employees within the business is equally important and the mainstay of a solid internal culture. A group of skilled-experienced, like-minded individuals who are focused on the customer and understand the business are like gold dust in terms of success. This is usually demonstrated as a (slightly clichéd but very descriptive) ‘can do’ attitude often reinforced by the business having all the previously mention attributes, including the right technology, effective processes and great people to work with.
In conclusion, pretty much any machine shop can offer you a ‘price’ – not all, however, can fully meet your needs and provide long-term business partnerships that will ensure your ongoing success.
To find out more about what Levy’s Machine Works Ltd. can do for you go to www.levysmachineworks.com or watch the short video at https://www.youtube.com/watch?v=6ZrAqmnrJ7o
Logical Continual Improvement – ISO 9001:2008 Certification
Being a progressive business, Levy’s Machine Works Ltd. recognizes the value of a robust quality management system and the importance of ISO 9001:2008 certification. But, in addition to enhancing the business’ credibility and clearly demonstrating that the service provided meets customers’ expectations, Levy’s pursuit of ISO 9001:2008 certification is also a logical continuation to its long-standing objective of continually improving in all areas, including:
- The ability to meet and exceed customer quality and delivery requirements
- The quality of the component parts produced
- The internal professional culture and focus on customer needs
- The consistency of all operations
- The business’ focus on efficiency and waste reduction
- The definition and communication of company processes
In addition to improving level of services to existing customers, having an internationally recognized quality standard provides certain other benefits, particularly in terms of increasing the potential to acquire new business.…and this, ultimately, will help propel Levy’s to the next level.