The Fabricated Metals Podcast

Saving Smarter in Metal Manufacturing: Why True Cost Reduction Starts Before the Quote

In this episode of the Fabricated Metals Podcast, host Dana Hansen sits down with Chris Kennard, Denny, and Dan from Process Metals Innovators (PMI) to explore what real cost savings look like in metal manufacturing—and why focusing on part price alone often misses the bigger picture.
The conversation starts with a common challenge: most customers begin with a request for a quote, but true savings are driven by much more than price. The team breaks down how design decisions, logistics planning, inventory strategy, and waste reduction all play a major role in total cost. From LTL versus full truckload shipping to PMI’s in-house trucking fleet, Denny explains how delivery control, timing, and returnable packaging directly impact both cost and customer experience.
Dan brings a process-planning perspective, highlighting how over-tolerancing, unnecessary GD&T, outdated drawings, and vague print notes can dramatically increase cost without improving part function. Small adjustments—like replacing welds with bends, using tabs for alignment, or forming features directly on a punch—can eliminate extra handling and reduce labor.
The episode wraps with a broader look at PMI’s end-to-end manufacturing capabilities, including stamping, fabrication, machining, powder coating, and inventory management. The key takeaway is clear: savings come from partnership, not just price. When manufacturers engage early and plan holistically, they unlock faster lead times, lower total cost, and more reliable outcomes.
⏱️ Timestamps
00:00 – Welcome to the Fabricated Metals Podcast01:10 – Why customers focus on price first02:00 – Logistics as a hidden cost driver02:33 – LTL vs full truckload shipping explained04:25 – Risks of LTL: delays, handling, and damage05:20 – PMI’s in-house trucks and delivery reliability05:45 – Returnable packaging and waste reduction06:30 – Custom racks and warehouse space savings07:30 – The true cost of expediting shipments08:55 – Safety stock and quick-ship strategies09:10 – Over-engineering and tolerance issues on prints11:00 – GD&T, ISO tolerances, and manufacturability13:00 – “Break all sharp edges” and costly print notes14:20 – Reducing welding with bends and interlocking tabs16:30 – Punch vs laser vs stamping: choosing the right process19:40 – Importance of solid models and clean CAD files21:30 – PMI’s end-to-end manufacturing flexibility23:00 – Stacking, batching, and vendor-managed inventory24:30 – Why warehouse space is an underrated cost26:50 – Final takeaway: savings come from early planning
💬 Key Quotes
“Savings come from partnership, not just price.”
“A simple note on a print can turn a three-dollar part into a much more expensive one.”
“When it goes on a PMI truck and we say it’ll be there at 10, it’s there at 10.”
“Over-tolerancing is one of the most common and costly issues we see.”
“Real cost reduction starts in the design phase, not after production begins.”
🔗 Relevant Links
Process Metals Innovators (PMI): https://www.pmilc.com
Free Fabrication Buyer’s Guide: https://www.pmilc.com/guide
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Automation in Manufacturing — How PMI Uses Robotics to Improve Quality, Safety, and Scale

Automation is no longer a future concept in manufacturing — it’s a competitive necessity. In this episode of The Fabricated Metals Podcast, host Dana Hansen is joined by Eric Lewis, Plant Manager at PMI, and Chris Conard, President of PMI, to explore how automation is reshaping modern metal fabrication.
From PMI’s first ABB welding robot to collaborative robots (cobots), advanced stamping automation, linear transfer systems, and high-volume tapping cells, this episode breaks down how automation improves consistency, ergonomics, and throughput — without replacing skilled workers. The conversation highlights how PMI evaluates which processes make sense for automation and how robotics help address ongoing labor shortages across the manufacturing industry.
You’ll also hear how safety systems, vision technology, sensors, and controls are critical to successful automation, as well as why partnering with experienced automation providers is key to long-term success. Whether you’re a manufacturer considering automation or a buyer evaluating suppliers, this episode offers practical insight into how smart automation supports scalability, reliability, and quality.
Timestamps
00:00 – Welcome to The Fabricated Metals Podcast01:00 – Why PMI views automation as a tool to enhance craftsmanship02:30 – PMI’s first automation investment: the ABB welding robot04:30 – Labor shortages, ergonomics, and consistency driving robotic welding07:00 – Transitioning to cobots and easier programming10:00 – Automating stamping lines with multi-robot systems13:00 – Maintenance, training, and safety challenges in automation15:30 – Linear transfer systems and increased production speed18:30 – New automation cells for tapping and assembly21:30 – Safety considerations and laser welding technology24:00 – How PMI identifies processes that should be automated27:00 – Training employees to work alongside automation30:00 – Why automation improves consistency and customer confidence33:00 – Closing thoughts and preview of the next episode
Key Quotes
“Automation isn’t about replacing people — it’s about enhancing craftsmanship, consistency, and speed.”
“Robots don’t get tired, and they don’t vary from part to part — that consistency matters to customers.”
“If the volume is there and the process is repetitive, automation becomes a smart investment.”
“Our employees didn’t lose jobs — they gained new skills and new career paths.”
“Consistency and quality are the biggest advantages automation brings to our customers.”
Relevant Links
Resources Mentioned
Fabrication Buyer’s Guide: https://www.pmillc.com/guide/
Let’s Connect
Process Metals Innovators (PMI): https://www.pmillc.com/
Dana Hansen on LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/
Chris Conard on LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/

Building the Future: How PMI’s Training Center Is Shaping the Next Generation of Fabricators

Every great product begins with people. In this episode of The Fabricated Metals Podcast, we dive into how Process Metals Innovators (PMI) is preparing the next generation of skilled professionals through its brand-new training center. Designed to blend classroom instruction with hands-on experience, this initiative is transforming how employees and students alike engage with manufacturing.
In this conversation, host Dana Hansen is joined by Chris Canard and Travis Parent, PMI’s Training Coordinator, to discuss how PMI University, school partnerships, and youth apprenticeship programs are building a stronger, smarter, and more connected workforce.
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Key Highlights from the Episode:
[00:00] Welcome and introduction to the show[01:00] Why PMI built a dedicated training center[02:30] How training supports employee retention and engagement[03:30] The creation of PMI University[05:00] Travis’s military background and passion for teaching[06:00] Hands-on learning: welding, CAD design, and machine training[08:00] Leadership, communication, and soft skills development[10:00] Partnering with local high schools and technical colleges[12:00] Student projects: fire pits, park benches, and reverse engineering[14:00] Collaboration with CVTC and the mobile welding trailer[16:00] How youth apprenticeships lead to national recognition[18:00] Changing perceptions of manufacturing careers[21:00] Opening pathways to real-world opportunities[23:00] How training supports PMI’s customers amid labor shortages[25:00] Introducing automation, robotics, and AI into training[27:00] The importance of cross-training and employee development[30:00] How PMI’s culture of learning drives excellence[31:00] Inviting schools and manufacturers to collaborate[32:00] Wrap-up and closing thoughts
Notable Quotes:
“It’s not just steel that’s important to us—it’s our people.” — Dana Hansen
“Training helps people feel important. It keeps them engaged and makes them want to stay.” — Chris Canard
“We’re not just teaching skills; we’re building confidence and curiosity.” — Travis Parent
“The more employees understand the ‘why’ behind what we do, the more engaged they become.” — Chris Canard
“Our investment in training is an investment in the future of American manufacturing.” — Dana Hansen
Resources Mentioned:
Fabrication Buyers Guide: https://www.pmillc.com/guide/
Let’s Connect:
Website: https://www.pmillc.com/Dana’s LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/Chris’s LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/

How PMI Partners to Solve Your Supply Chain Issues

Every great product begins with a promise—but that promise can quickly unravel when supply chain problems stand in the way. Missed deadlines, scattered suppliers, and costly delays don’t just disrupt operations; they jeopardize trust and growth. Instead of battling constant roadblocks, imagine having a clear, reliable path that frees your time, eliminates inefficiencies, and ensures your projects run smoothly from start to finish.
In this episode of the The Fabricated Metals Podcast, we talk about how PMI can help eliminate some of your supply chain issues, what makes us unique and positions us as a reliable supplier, and how we can turn many of your biggest problems into lasting solutions.
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Key Highlights from the Episode:
[00:01] Introduction to the show
[00:57] Who PMI is and why customers trust them
[02:04] How PMI stands out from other vendors in the supply chain 
[05:24] How PMI has grown based on the different markets it serves
[07:41] Ways PMI can simplify your supply chain
[08:22] Real-life customer story: how PMI delivered solutions
[11:49] Pain points of sourcing parts overseas—and PMI’s solutions
[14:12] How PMI delivers exceptional customer service 
[16:10] Automation at PMI and how it helps meet demand
[17:20] A quick recap and how to take the next step
[19:05] Wrap-up and end of the show
Notable Quotes: 
“You are very busy when you have too many suppliers.”
“Don’t be afraid to ask for anything; let’s know what issues you’re running into with different types of parts.”
“If we can’t solve your problem, we can find someone who will.” 
 
Resources Mentioned: 
Fabrication Buyers Guide: https://www.pmillc.com/guide/
Let’s Connect:
Website: https://www.pmillc.com/
Dana’s LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/
Chris’s LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/

Innovation, Ownership, and Customer Focus: The PMI Story

Innovation, customer focus, and 100% employee ownership come together in a story of growth, resilience, and purpose. It’s a journey that begins with humble roots, evolves through decades of dedication, and finds strength in putting people first. At its core is the belief that customers deserve solutions that simplify challenges, reduce stress, and create lasting value. Along the way, employee ownership has transformed not only the way business is done, but also the way people work together—building trust, loyalty, and a future shaped by shared success.
In this first episode of the The Fabricated Metals Podcast, we dive into the world of Process Metals Innovators (PMI)—our beginnings, the products we create, the customers we serve, and why becoming a 100% employee-owned company has been such a meaningful milestone. Joining the conversation are Dana Hansen, PMI’s Sales and Marketing Manager, and Chris Conard, President of PMI, who have worked together for over 20 years to build strong relationships, simplify supply chains, and deliver lasting value to customers.
Tune in now!
Key Highlights from the Episode
[00:01] Introduction to the show
[00:50] PMI’s history: how it started and grew into a one-stop shop
[04:12] Meeting customer needs in the supply chain
[05:22] Why working with one supplier can save inventory headaches
[06:27] What partnering with PMI looks like for customers
[08:33] How outsourcing with PMI saves time
[09:20] PMI’s customer base and how they are served in today’s climate
[10:45] Diversifying the supply base—and how PMI meets demand
[11:58] Why PMI started the The Fabricated Metals Podcast
[13:48] Becoming employee-owned in 2021—and what it means to the team
[15:10] Wrap-up and closing thoughts
Notable Quotes
“You can reduce a lot of stress in a day by putting the work of managing so many different suppliers into just one.”
“If you are dealing with multiple suppliers, you are probably killing more inventory than you want to.”
“It’s human nature to be comfortable with something you have been doing for a long time.”
Resources Mentioned
Fabrication Buyers Guide: https://www.pmillc.com/guide/
Let’s Connect
Website: https://www.pmillc.com/
Dana’s LinkedIn: https://www.linkedin.com/in/dana-hansen-46a61114/
Chris’s LinkedIn: https://www.linkedin.com/in/chris-conard-bb2b5016/