Modern Machine Shop-ERP and Process Changes Increase Shop’s Revenue 64% YoY

Modern Machine Shop - ERP and Process Changes Increase Shop's Revenue 64% YoY

“You don’t know how much waste you have until you address it,” says James Marzilli, founder and president of Marzilli Machine, a high-end component manufacturer located in Fall River, Massachusetts. Marzilli has been running his shop since 2011, but even after adopting a simple ERP system in 2013, managing the shop and ensuring its efficient operation was a grueling task. “When I looked at shops that were one- or two- or four-man shops, the guy that ran that place was always broke, stressed out.

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Importance of CMM Inspections

CMM probe tip coming down to inspect the part.

Welcome to this week’s installment of Marzilli Monday. Today, we turn our attention to the precision-driven world of Coordinate Measuring Machine (CMM) inspections. We dive into the benefits of CMM Inspections, discussing how they play a pivotal role in our Quality Assurance systems. As well as how they elevate machining precision, quality control, and overall manufacturing efficiency. A CMM inspection could be just what you need to take your business or product to the next level. Stay tuned to discover how CMM inspections not only ensure the utmost accuracy in machined components but also empower manufacturers with data-driven insights for continuous improvement.

Probe tip in milling machine.

The Process.

The CMM inspection process starts right when a work order is created. The planner will decide if a CMM program is necessary based on the complexity of the part, and will add a line to the work order signifying this. Once the CMM Inspection line is added to the work order, our in-house ERP system, ProShop, alerts the CMM Programmer and places the work order on his to-do list. This allows the CMM Programmer to stay updated on incoming work and allows him to begin creating the program before the cutting even starts.

 Once the program is created and the first part has been cut, Quality Control will do a first run of the program using the first part. From there, the CMM Programmer will work out any issues found in the program, and verify the program is perfect. Once the program has been verified and is working correctly, the CMM Programmer will save the program to the company’s server, for future work orders, and as a reference for future parts. As parts continue to get manufactured, the CMM Programmer will save the necessary inspection reports to the server as well. If the customer requests these reports, we are easily able to locate them, print them, and ship them with the parts. Depending on a part’s complexity, a CMM program can sometimes be time-consuming to create. However, having the ability to create the program before a part is even cut, and the added efficiency of the CMM inspecting the parts vs having to inspect them manually, makes all the difference in terms of time saved and profitability.

CMM probe tip coming down to inspect the part.

The Benefits.

The benefits of CMM inspections make them necessary for Precision CNC Machine shops. The accuracy of CMMs alone is enough to make them crucial. The technology gives you the ability to almost instantly measure dimensions that would’ve previously been viewed as difficult or required a stand-alone tool. The efficiency you gain by being able to place a part on a machine and having it inspected quickly, accurately, and automatically, no matter the complexity, is unmatched. With technology getting better every day, 3D scanning is a new, innovative method of metrology Marzilli Machine has adopted recently. 3D scanning has the added benefits of reverse engineering & design for manufacturing. This is because higher-end machines can create a highly accurate 3D model based on the part you scan. This gives the manufacturer a better visual representation of the part and allows us to work directly with the engineers to improve manufacturing conditions. This can drastically decrease production costs, and increase profitability. Another benefit of these CMM inspections is the level of traceability. Highly detailed CMM reports can easily be created and sent to a customer right from the software. These reports are also able to be exported, so you can save your data. The CMM program is also savable, so you can store it, and reuse or reference it in the future.

Meeting Marzilli – The CEO

Welcome to Marzilli Machine Co’s third installment in the Meeting Marzilli series, today we talk with Lee Marzilli, the CEO of Marzilli Machine Co. Learning more about the owner of the company. Lee’s entrepreneurial journey starts in college, where she attended the University of Rhode Island, earning her Masters of Business Administration, as well as an undergrad in Psychology. In this blog we dive into Lee’s early ambitions before becoming a business owner, we then talk about the effect the business has had on her, and her future goals for Marzilli Machine Co. During our conversation, Lee also reflects on the pivotal moments that shaped her leadership style and the challenges she faced in the male-dominated manufacturing industry. As we cover her personal and professional growth, we get valuable insights into the evolving industry of CNC Machining.

We start today off discussing Lee’s education, then moving on to life before the business, what it was like starting Marzilli Machine, and any future goals she has for the company. As mentioned earlier, the first thing I discussed with Lee was her college education. I learned that she attended the University of Rhode Island. Where she earned her Masters of Business Administration, as well as her undergrad in Psychology. Following college, she planned on joining her mother in running the family bookkeeping business, Lee always had the goal of starting her own business, it runs in her blood. However, the bookkeeping business didn’t pan out the way she expected. Her mother wasn’t the only one in her family who had experience running a business. Lee’s grandparents owned a shop, and were active in CNC Machinery sales, introducing her to the industry at a young age. During her college studies, Lee secured a position as a Rite AID store manager, where she was able to start sharpening her team leadership skills from a young age, far before Marzilli Machine Co. would become a thing. This would eventually lead to her college graduation in 2013, where she would ultimately leave Rite AID, and join her husband, Jamie Marzilli, in leading Marzilli Machine Co. Onboarding into the manufacturing industry is not an easy task for anybody. The possibilities of CNC Machining, are seemingly endless, and always evolving, making it a notoriously difficult industry to master. However, in just three short years, Lee knew the industry like it was the back of her hand. She was able to learn and retain everything necessary to turn a piece of stock, into a complete part. I wanted to learn more about her onboarding process, as someone relatively new to the industry myself, I too know about some of the difficulty that comes with CNC Manufacturing. She made it clear that her biggest struggles when learning manufacturing were working drawing related. Deciphering complex prints can be extremely difficult, even for engineers, so it’s no surprise this was mentioned. Yet she was still able to pick this skill up, as well as everything else necessary, in that three year time frame. A true testament to her quick learning abilities.

We then moved on to discussing her work today, and how running the business has evolved over the years. When I asked her about her day-to-day focus, she went into depth about her accounting responsibilities. Lee always has her eyes on the numbers, and is constantly thinking about ways to take Marzilli Machine Co. to the next level. She is responsible for things such as in house finance, & payroll. Things that leave zero room for error. Not only does she handle this, but she also plays a huge role in the businesses quoting process. She has also been training the internal sales team to learn how to help her out with quoting, as the business is more demanding now than ever before. In fact, when I asked Lee about how being an entrepreneur has effected her personal life, she explained that she always feels like she is working, and now has little to no time to enjoy external activities. She stated that she enjoys her work, and is following her dream, so it doesn’t bother her, but it definitely took an adjustment period. I could only imagine how tiring that could be. I wondered what possibly could keep an individual so motivated, so naturally that had to be my next question, what keeps you going every day? Lee had an instant answer, almost before I finished asking the question! She said, without a doubt, her kids and family are the reason she’s so driven. She stated that she loves the fact she has free time to raise her children, and is not bound by a work schedule, as she is able to work from home as well. And she mentioned how it’s nice being able to bring the families dog to work, to spend time with the crew in the office. I switched up the conversation at this point to learn a bit about the future of the business. Lee had lots to say, making it clear to wants to improve the life of employees as much as possible. She is looking to add an in house daycare, to help decrease the living costs for employees. Not only a daycare, she also mentioned an in house gym, and even an in house school for machining, to allow employees to further their industry knowledge. Lee also put emphasis on how important the upcoming expansion is, so we can have enough space to add these amenities to the facility. The expansion is looking to be completed by spring 2024! During this expansion Marzilli Machine Co. is looking to heavily improve on automation skills, capitalizing on lights out machining to improve employee satisfaction and virtually delete some of the tedious tasks operators may have to deal with. Stay tuned for next weeks blog where we will be taking a deeper look at the upcoming expansion.

The Benefits of CNC Turning

The CNC lathe machine rough cutting the metal shaft parts with l
The CNC lathe machine rough cutting the metal shaft parts with l

CNC Lathe about to begin turning operation

First and foremost, CNC turning enhances precision and accuracy. The computerized control of the machining tools allows for consistently tight tolerances and exacting specifications, reducing errors and minimizing material waste. Furthermore, CNC turning increases efficiency. With automated tool changes and continuous operation, it significantly reduces downtime, resulting in higher productivity and faster turnaround times for production runs. CNC turning also facilitates complex and intricate designs. The ability to create intricate shapes, threads, and profiles with ease enables the production of sophisticated components and parts. Cost-effectiveness is another advantage, as the process requires minimal manual labor and reduces the risk of errors that can lead to costly rework or scrap. In this blog, we will dive into each of these advantages, to find out how CNC Turning can personally benefit your CNC Manufacturing projects.

Live tooling in action during CNC Lathe turning operation.

Precision: CNC lathes are highly accurate and capable of producing intricate parts with tight tolerances. They can consistently repeat the same operations with minimal variation, leading to high-quality, reliable components.

  • Versatility: CNC lathes is capable of creating anything from simple to complex geometries. It’s suitable for producing prototypes, one-offs, and mass production runs, making it versatile for almost all industries and applications.

  • Efficiency: CNC turning is an efficient process that can run 24/7 with minimal human intervention, reducing labor costs and increasing productivity. Automated tool changes and tool path optimization help streamline the manufacturing process.

  • Consistency: CNC turning ensures consistent part quality and dimensional accuracy throughout a production run. This consistency is crucial when interchangeability and precision are essential.

  • Rapid Prototyping: CNC turning is suitable for prototyping because it allows for quick design changes and adjustments. This enables us to test and refine your designs before full-scale production.

  • Cost-Effective for Production: CNC is a cost-effective solution for large production runs due to its efficiency, consistency, and low labor requirements.

  • Integration with CAM Software: CNC Lathes machines can be easily programmed using our in house Computer Aided Manufacturing (CAM) software, which simplifies the design-to-production workflow and reduces the potential for errors.

  • Design for Manufacturing: Design for Manufacturing (DFM) in CNC turning allows us to work with your team to streamline the design process, minimizing complexity, reducing the risk of errors, and optimizing tolerancing & material selection. These benefits ultimately lead to a cost-effective manufacturing process and higher quality parts.

Brief History

CNC Turning hasn’t always been what it is today. The industry shifted from punched cards, to Computer Numerical Control (CNC) in the 1950s, paving the way for incredible precision and automation. CNC Lathes could now complete complex designs with ease, making it a staple across various industries including aerospace, medical, firearms, defense, and many more. As tech continued to progress, so did the capabilities of CNC Turning. Lathes began to adapt to new materials like composites, and alloys. Today, CNC lathes have evolved into highly complex and intricate machines. They now have capabilities such as multi-axis control, real time monitoring, and live tooling. Not only did this increase efficiency for CNC turning, but it created new possibilities in terms of design complexity and production speed. In conclusion, the history of CNC turning continues to be innovative and exciting. From manual lathes to the computer controlled facilities we have today, these machines have come a long way, shaping the world of modern manufacturing. Be sure to stay updated on the blogs as we continue to cover upcoming industry innovations, as well as all the modern technology we use on a day-to-day basis to complete your manufacturing needs with ease. Contact us today to find out how we can help with your CNC Turning projects. Marzilli Machine Co. currently has 4 lathes, as well as live tooling and bar feeding capabilities. Call us today at 508-567-4145 or request a quote.

Meeting Marzilli – The President

Welcome to Marzilli Machine Co’s second installment in the Meeting Marzilli series, today we talk with Jamie Marzilli, the President of Marzilli Machine Co. Learning more about the owner of the company. Today’s post begins with us discussing life before the business, we then talk about things like the impact the business has had on him, as well as what the future holds for Marzilli Machine. We go into detail about the upcoming expansion, and how it will change the business substantially. As well as why he started machining, and what the trade means to him. Stay tuned for next week when we discuss CNC Turning in the next installment of Marzilli Monday!

We will start today off by talking about Jamie’s early professional life, What he did, and how he got to where he is today. One of the first things I asked him about was his education, and how he learned about machining & manufacturing. Jamie started high school at Tiverton High School, he then transferred to Diman Regional Vocational Technical High School after his freshman year, hoping to get into carpentry. After learning that the carpentry shop was full, Jamie’s choices were limited, as transfer students can’t explore all the trades at Diman such as regular applicants. Ultimately Jamie chose Machine Shop, his decision being driven by the fact that he knew people in the trade who were doing well for themselves, and he thought manufacturing was interesting. After a few weeks in the shop, he was hooked, and learning new things daily. After graduating from Diman Regional Vocational Technical High School, Jamie went on to start his career as a job shop machinist. He spent most of his career at one shop, climbing the ranks into management. After a while, he became dissatisfied working with people who weren’t machinists, fueling the desire to start his own business. That was until one day, Lee Marzilli, Jamie’s wife, and CEO of Marzilli Machine Co., dared Jamie to start the business, in a game of truth or dare. This decision led us to where we are today. When I asked Jamie how his day to day has changed, he had a ton of answers for this one question. He talked a lot about his schedule, and how he feels as if he is always working. Even when away from “Work”, Jamie states that he is “always thinking about what’s required to get to the next level”. He’s always looking for ways to make himself better at what he does. I asked Jamie what he enjoyed most about owning a business, to which he replied “The freedom to choose my own path”. He talked about the drive he has to teach the next generation, and how he wants to have a lasting impact on the future of manufacturing. He is very thankful to have been given a unique skill set that allows him to help the next generation grow. And he feels an obligation to pay it forward.

I then changed the conversation to find out how he feels about being a business owner, asking him things such as how he stays motivated, and how the business affected his personal life. When it comes to motivation, Jamie had a lot to talk about. He mentioned how his kids, family, and his team keep him going. He feels the need to “finish what he started”, and he wants to hand a successful, strong business to his kids. Furthermore, he also mentioned that motivation isn’t everything, and discipline is a very important trait to have. When asked about his personal life, Jamie said that everything has changed. He has to stay mindful of his home-work life balance, and he feels “guilty” when not working. He stated that being a business owner has changed who he is as a person, and has become “a part of the definition of who he is”. I then asked about his struggles early on as a businessman, he talked about the difficulty of learning to think differently. He spoke about how he can’t think like a machinist anymore, and he has to look at things from multiple perspectives. I then shifted the conversation towards the future of Marzilli Machine Co. I wanted to know more about Jamie’s goals, and where he sees the business in a few years. When I asked him about his short term goals, he talked about his focus on the upcoming expansion. Putting most of his efforts into getting the company into a new, much larger facility, about 3x larger than our current shop. Jamie has a goal of reaching 10-12 million gross sales by 2028, and will do whatever it takes to get there. He states this will take around 50 employees to achieve. As of now, we are planning to have our grand reopening in spring of 2024. I then asked him how he plans on hiring that many people, finding 20 more like-minded, hard-working employees is no easy feat. He said that while important, talent isn’t everything, hard work is. He enjoys training new individuals through precise systems, and teaching them valuable skills. In fact, prior to owning the business, Jamie wanted to be a teacher. Going as far as getting his teaching license, he wanted to teach machining at his old school, however the position wasn’t available, leading us to where we are today. Everything happens for a reason.

Why Choose CNC Milling?

5 Axis milling machine cutting large angle for automotive part.

CNC milling, with its roots dating back to the mid-20th century, has evolved into a cornerstone of modern manufacturing. It relies on computer-guided precision to cut components from raw materials, enabling the creation of everything from intricate aerospace parts to custom firearm assemblies. The diversity of CNC milling machines ensures that there’s a machine tailored for almost any application, providing the industry with a versatile and adaptable tool for various projects. In this blog, we’ll discuss CNC milling, its numerous types and their applications, the benefits of choosing CNC milling for your project, ultimately arming you with the knowledge to optimize your manufacturing projects.

CNC mill cutting a small part with intricate angles, G-Code overlay has been added to image

Precision.

CNC (Computer Numerical Control) milling is a sophisticated machining process that relies on computer programs, typically G-Code, to precisely control milling machines. These programs control critical parameters such as cutting speeds, feed rates, and tool paths, ensuring every operation is executed accurately. The versatility of CNC milling is unmatched, enabling the machining of almost any material, from metals and plastics to composites and exotic materials. Moreover, CNC milling machines can operate on different axes, allowing for intricate and complex geometries that would be challenging to achieve using traditional machining methods. The introduction of 3rd, 4th, or 5th axis milling machines has expanded CNC milling’s capabilities, making it ideal for industries like aerospace, medical, firearms, prototyping, and defense, where multifaceted components are standard.

When it comes to precision, CNC milling has set new standards, with tolerances as tight as 0.0005 inches now being the standard in world-class machine shops. This level of precision not only reduces the need for extensive post-processing but also elevates the overall quality of the end product. Reduced post-processing and improved quality are only two advantages of CNC milling. It also offers enhanced efficiency, as these machines can operate continuously with minimal human intervention, resulting in reduced production time and labor costs. The repeatability and consistency of CNC milling make it an invaluable tool for mass production, where identical designs must be replicated across multiple workpieces. As CNC milling continues to evolve, it has become a cornerstone of modern manufacturing, influencing various industries and allowing precision that was once deemed impossible to produce.

3rd axis milling machine at a stand still, preparing to continue milling the workpiece.

Efficiency.

The benefits of CNC milling are not limited to precision and complexity. The efficiency brought to the table by CNC mills is a game changer. As mentioned before, the need for labor-intensive handwork, & post-processing is drastically decreased when using a proper milling machine. Additionally, CNC mills excel in significantly reducing the time it takes to produce parts. They succeed in minimizing material scrap, & operating unattended for extended amounts of time. CNC mills were designed with efficiency in mind, the automated tool changing system is another component that will help drive productivity and cost-effectiveness across numerous industries. Rapid prototyping and design iteration are simplified thanks to the efficiency benefits, meaning that prototypes and testing can easily be completed before committing to mass production. Successful rapid prototyping allows for parts to be refined and optimized, meaning that mass production will be completed precisely, and timely. Ultimately resulting in successful production schedules, and optimized resource utilization. Not only are you able to machine more intricate parts, while holding tighter tolerances, CNC milling allows you to do all of it at a faster rate.

Complexity.

Arguably the greatest benefit unlocked by CNC milling is the unparalleled complexity. 3D features that would challenge the limits of traditional methods, not only become feasible with CNC mills, but highly repeatable as well. 5th axis milling provides the ability to machine at multiple angles & orientations, without the need for repositioning the part, this is a valuable, time saving capability for intricate, multi faceted parts. 4th and 5th axis milling has become essential for milling parts with multiple angles and complex geometries. However, not all parts require 5th axis milling, in fact, 3rd axis milling is suitable for most basic parts. The number of necessary axes depends on the job, and is a direct correlation of the mills’ capability to machine multi sided parts. In industries such as aerospace, medical, firearms, defense, & OEM, tight tolerances and complex geometries have become the norm, meaning CNC milling isn’t going anywhere. The technologies’ capacity to create intricate and custom designs, while maintaining consistency and accuracy, has expanded the possibilities for innovation and product development. Ultimately enabling manufacturers to craft parts with intricate curves, and compound angles, that may have been seen as impossible in recent years.

Meeting Marzilli – The Author

Welcome to Marzilli Machine Co’s official “Meet the Author” post! Today we are going to talk a bit about my professional background, my role within the company, my journey up to this point, and what I’m looking to do in the future. This week’s blog also marks the launch of our new blog series called “Meeting Marzilli.” In this series, we will introduce you to a new employee with every post, and dive into their roles, and stories within the company. We plan on creating 2 Meeting Marzilli posts per month, releasing them every other Monday. This series will ensure a steady flow of engaging content intimate to the company, and will fill the gaps between your regular Marzilli Mondays.

My Background

Hi! My name is Cody, I am a 19-year-old from Fall River, MA. I started off studying mechanical engineering as well as architecture in a vocational technical high school. From there I was able to secure a job in the field, working on snubber & piping design. I enjoyed it for a while, but after being exposed to engineering for some time, I realized the career choice I made did not properly suit me, and I needed to find something new. I was more interested in learning new skills that could potentially lead me to becoming my own boss. I had a goal of becoming an entrepreneur. Thankfully I found Marzilli Machine Co. A machine shop local to me, filled with like-minded individuals who will stop for nothing but success. After securing a position as an Executive Assistant, I was eager to grow. Starting out, I was tasked with things such as building systems & documenting them through SOP’s, data entry, and some inventory management. Though these tasks were not exactly fun, I was able to learn a lot about building successful systems, implementing them, and doing what it takes to help the business succeed. Time passed, and I began picking up more responsibilities. I was able to show what I am capable of. Eventually, Information Technology became my responsibility, where I was able to learn a lot about domain management, as well as troubleshooting computer issues efficiently. After a few months, I found myself on the production floor. Running CNC mills and CNC lathes was something entirely new to me, the only prior “experience” I had was my ability to read prints from my background in drafting. With some proper training, and a solid management team, operating these machines was another skill I was able to learn. However, operating isn’t the only thing that comes with that position, I did lots of work with Quality Control, teaching me about inspection and proper measuring techniques. As well as shipping and receiving, where I was able to learn about the flow of production, inside the shop and out. Once I was comfortable with these tasks, I grew back into my office position, where I am today. But now I have the flexibility to return to production if necessary. Being a well-rounded individual within the company is something I am very proud of.

The Present.

Returning to the office was something I was a bit stressed about. I really enjoyed being on the floor, however my skill set was more valuable at my desk, and I knew it was what needed to be done. Thankfully, since I’ve returned to the office I’ve only picked up more skills, and continue to grow every day. As mentioned before, when I started here my goal was to become an entrepreneur, which is why I took the assistant position, it gave me a chance to work at the hip of one. I’ve learned countless lessons from this experience, and ill be the first to tell you, being an entrepreneur isn’t as glamorous as it seems. Everybody wants to be their own boss, but very few actually know what it takes, and even fewer have the work ethic to do so. It is not an easy feat, and working hand in hand with Jamie has showed me that I should slow down, and take advantage of the opportunities given to me first, before I go out and try to make my own. Currently, my main priority is the marketing for the company. After revamping the entire website, I am now tracking analytics, creating blogs like the one you are reading now, and doing everything I can to get Marzilli in front of more eyes. I still manage the IT department, and I write the occasional SOP, but marketing is definitely where the majority of my time is spent. My goal for the foreseeable future is to continue with Marzilli’s marketing, and grow the companies social media presence exponentially. You can expect new content to be published weekly, in the form of blog posts, company info, announcements, etc. If you made it this far, I’d like to give you a little preview into our upcoming blog topics, as well as provide you with a place to request specific blog topics you would like to see published. My goal with writing this is to educate the audience about CNC manufacturing, as well as provide you guys with an inside look at the company. My next three scheduled blogs include an in depth look at “CNC Milling”, a new installment of “Meeting Marzilli” where I will be personally interviewing Jamie Marzilli, the president of the company, and an in depth look at “CNC Turning”. If you have any specific blog requests, please email them to me at cody@marzmachine.com, and I will be sure to take them into consideration!