Quality Fabrication Never Sleeps in Portage, Indiana
In Focus
Imagine a metal fabrication facility where robots cut, form, and stack steel parts through the night while most of the world is off the clock. At Ryerson’s smart factory in Portage, Indiana, this isn’t science fiction—it’s reality. And it's redefining what’s possible in modern metalworking.
The No-Touch Metal Fabrication Process
While many metal service centers have automated one or two steps in their process, Ryerson’s Portage facility delivers a fully automated, end-to-end solution for fabricating metal parts.
Here, automation goes far beyond cutting and forming. It integrates every step of the metal fabrication process—from loading raw materials to packaging finished components. The only time human hands touch the product is to tag and band it for shipment.
This is next-generation automated metal fabrication, built to enhance speed, precision, and scalability.
Real-World Example: Automated Production for Bottling Facility Subfloors
Take a recent project: a bottling factory needed 15,000 subfloor channels—each requiring precision forming. Traditionally, a job like this would rely on multiple service providers, manual labor, and complex logistics.
At Ryerson’s smart factory, the job stayed in-house, executed with robotic forming and stacking capabilities:
- Each part took just 2.5 minutes to form with a robotic press brake, which automatically flipped and stacked the parts.
- While a human operator might move faster during a single shift, Ryerson’s lights-out operation ran through the night—achieving higher output without supervision.
- Finished parts were automatically stored in one of hundreds of queue-ready locations, prepared for fast delivery without bottlenecks.
Lights-Out Manufacturing: A Solution to Labor Shortages
One of today’s biggest challenges in metal fabrication is the ongoing labor shortage. Ryerson’s smart factory model provides a scalable answer—through robotic fabrication that doesn’t clock out.
- End-to-end automation means that cutting, forming, and racking can continue without interruption—even when staffing is limited.
- Machines run through shift changes, weekends, and holidays, ensuring that your metal parts are fabricated and delivered on time.
Whether you're dealing with workforce constraints or unexpected demand spikes, Ryerson’s approach ensures your supply chain stays ahead.
Elevating Metal Fabrication Quality Through Automation
Efficiency matters—but so does quality. That’s why Ryerson’s Portage facility includes automated quality control baked into every step of the process.
- Every part formed is scanned by an integrated laser inspection system to confirm exact specifications.
- If a bend is under-formed, the robotic system makes instant corrections—reducing rework and ensuring consistent part quality.
- This in-line quality assurance minimizes human error while freeing skilled workers to focus on more complex fabrication tasks.
For customers with tight tolerances, this level of fabrication precision helps prevent costly delays or rejects.
Shaping the Future of Smart Metalworking
Ryerson’s smart factory isn’t just keeping pace—it’s setting the pace for the future of metal fabrication. By investing in fully automated systems and modular factory models, Ryerson is:
- Supporting reshoring and domestic manufacturing growth
- Delivering faster, more reliable lead times
- Scaling production without sacrificing quality
What This Means for Metal Buyers
Partnering with Ryerson means more than sourcing raw material. It’s about tapping into a metal fabrication solution that’s ready to:
- Deliver precision-formed parts quickly and consistently
- Flex with your business as needs change
- Reduce quality risks and production delays
- Strengthen your entire manufacturing supply chain
As manufacturers face new challenges, from labor shortages to supply chain volatility, smart factories like Ryerson’s Portage facility offer a proven path forward.
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