By bringing pipe bending processes in-house, we have achieved reduced outsourcing costs and shorter delivery times.

For those in the manufacturing industry, "increasing outsourcing costs" and "delivery delays" are likely major challenges.
As a solution to these challenges, this article proposes bringing pipe bending processes in-house.

In-house pipe bending processes offer not only direct benefits such as cost reduction and shorter delivery times, but also multifaceted value that strengthens corporate competitiveness through improved quality, enhanced customer service, and increased internal technical capabilities.

This article compares the advantages and disadvantages of outsourcing and in-house pipe bending processes, and introduces specific examples of companies that have successfully implemented in-house bending. Furthermore, it provides a clear explanation of how to choose the "pipe bender," which is essential for in-house production, so please read it to the end.

Outsourcing processing to external specialists ("outsourcing") and bringing production in-house ("in-house production") each have different advantages and disadvantages. Here, we objectively compare the characteristics of both options to help you determine which choice is best for your company.

■ Comparison of outsourcing vs. in-house production

【merit】

• There is no need to introduce specialized equipment such as pipe bender, which helps to keep initial costs down.
• By reducing capital investment, funds can be used for other growth areas and core businesses.
• High-quality and consistent processing can be expected from our outsourced processing company with many years of experience.
• Even for special shapes or complex bending processes, specialized companies can often handle it.

[Disadvantages]

• Processing costs tend to be high, and outsourcing costs can increase as production volume increases.
• Depending on the production status of our subcontractors, it may become difficult to handle projects with short deadlines or urgent requests.
• Processing technologies and experience may not be retained within the company, potentially leading to a loss of opportunities for talent development.

【merit】

• Reducing outsourcing costs will lead to improved cost competitiveness in the long run.
• Because we can control delivery dates in-house, we can respond more flexibly to urgent orders and projects with short deadlines.
• A speedy response is expected to improve customer satisfaction and trust.
• By controlling processing quality according to our own standards, we can improve the uniformity and reliability of our products.
• Accumulating processing technology within the company leads to improved technical skills and knowledge transfer among employees.

[Disadvantages]

• Investment in equipment such as pipe bender and a review of the factory layout (securing installation space) are necessary.
• In some cases, costs may be incurred for securing personnel to operate the equipment and for training them to acquire the necessary skills.
• Equipment maintenance and periodic inspections must be managed in-house.

After comparing the pros and cons, we will introduce specific examples of companies that have successfully brought pipe bending in-house. We will delve into how they overcame challenges such as "increased outsourcing costs" and "delivery delays" that many companies face, and what results they achieved.

Ogawa Metalwork Co., Ltd. manufactures parking sign frames and bollards, and a large order prompted them to consider "in-house bending." Previously, they relied on outsourcing, which presented challenges in meeting tight deadlines and managing costs. Therefore, they introduced a pipe bender (Elcolina Mega bender MG030). Since its introduction, they have been able to handle pipe bending in-house, resulting in a monthly reduction of 800,000 yen in outsourcing costs.

▼Click here for more details on case studies and how to use them▼

YST Corporation had previously relied on outsourcing for its bending process, which sometimes resulted in lost orders due to challenges in meeting deadlines. To maintain stable product quality while meeting short deadlines, a review of their processes and equipment was essential. This led to the introduction of a ring roller bender (Ercolina CE40MR3). After implementation, they were able to process products in as little as one day, and their response time became even more flexible.

▼For more details on case studies and instructions on how to use the ring roller bender, please click here▼

To successfully bring pipe bending in-house, it's crucial to select a pipe bender that best matches your company's needs. Here, we'll explain three key points to consider when choosing bender. Checking these points beforehand will help prevent mismatches after implementation, maximize return on investment, and allow you to reap the benefits of in-house production.

When choosing a pipe bender, the most basic and important thing to check is its processing capacity. Make sure the machine you are considering can handle the "material (iron, stainless steel, aluminum, copper, etc.)", "outer diameter (Φ)", and "wall thickness (t)" of the pipes you will primarily be working with.

Furthermore, the "minimum bending radius (R)" and "maximum bending angle," which affect the degree of design freedom, are also important.
For example, if you frequently perform complex bending processes that fit into confined spaces, you will need a machine capable of handling small radii. If possible, consult with the manufacturer and request a test processing using the materials you will actually be using to check the processing accuracy and finish. This will provide information that cannot be obtained from catalogs alone, leading to a more reliable selection.

If a machine can only be operated by highly skilled personnel, the benefits of in-house production cannot be fully realized. Whether on-site workers can operate it intuitively without special training greatly impacts production efficiency. Easy setting of bending angles via digital display, operation with few buttons, and ease of mold change are crucial elements in high-mix, low-volume production. These features reduce quality variations due to individual operators and enable stable production.

Furthermore, a safe working environment is essential not only for improving productivity but also for retaining employees. Make sure that sufficient safety measures, such as emergency stop buttons and safety covers, are in place.

Many factories face the challenge of limited space. Therefore, before implementation, it is necessary to consider not only the dimensions of the pipe bender itself, but also whether sufficient workspace can be secured considering the length of the pipes to be processed. Furthermore, a highly portable model with casters allows for flexible adaptation to changes in factory layout or when temporary workspace needs are required.

Bringing pipe bending processes in-house offers significant advantages beyond simply reducing outsourcing costs. These include shorter lead times, improved quality, enhanced customer service, and the accumulation of technical expertise, thereby boosting a company's overall competitiveness. One example shows that in-house production has resulted in substantial improvements, such as a monthly reduction of 800,000 yen in outsourcing costs and a lead time reduction of more than a week.

When bringing production in-house, it is important to select equipment while keeping the following three points in mind.

• Do they have the processing capabilities to handle our own products?
• Is it easy for anyone to use and safe?
• Is it a size and portability that makes it easy to operate even in limited factory space?

Companies currently facing challenges such as increased outsourcing costs and meeting delivery deadlines should definitely consider bringing pipe bending processes in-house.
Implementing appropriate equipment is a significant step towards improving productivity and profitability.

Let's achieve in-house production with pipe bender!

If you're having trouble with bending processes, please contact us for a consultation.