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Manufacturing Myths
How Outdated "Best Practices" Are Slowing You Down
Issue 029
Manufacturing teams work hard to improve efficiency, but sometimes the biggest slowdowns come from well-intentioned “best practices” that no longer work.
From over-tightening tolerances to adding unnecessary secondary operations, many long-standing manufacturing beliefs are costing companies time and money without actually improving quality.
Let’s break down some of the most common precision manufacturing myths—and what you should be doing instead.
Myth #1: Tighter Tolerances Always Mean Higher Quality
🔹 The Belief: The more precise the tolerance, the better the part.
🔹 The Reality: Not every component needs extreme precision—and forcing ultra-tight tolerances on non-critical features can increase machining time, scrap rates, and costs without adding real value.
🔹 Example: A medical device manufacturer required a ±0.0005” tolerance on a non-critical plastic housing component.
The result?
❌ Longer machining times due to excessive precision requirements
❌ Higher rejection rates from parts slightly outside spec
❌ Unnecessary cost increases
💡 The Fix:
✅ Determine critical tolerances vs. non-critical tolerances—not all dimensions need extreme precision.
✅ Work with manufacturing engineers early to optimize tolerances for cost-effective production.
✅ Apply tight tolerances only where functionally necessary, not across the entire part.
Myth #2: More Secondary Operations Improve Part Quality
🔹 The Belief: Adding additional machining, finishing, or inspection steps will result in higher-quality parts.
🔹 The Reality: Too many secondary operations slow down production, drive up costs, and can introduce unnecessary complexity.
🔹 Example: A stamped electrical component was being sent for extra polishing and grinding, even though the added finishing wasn’t functionally necessary.
The result?
❌ Longer cycle times and bottlenecks
❌ Higher labor and equipment costs
❌ No measurable improvement in part function
💡 The Fix:
✅ Only add secondary operations when necessary for function or appearance.
✅ Use in-die tapping or forming when possible to eliminate extra steps.
✅ Automate quality control with vision systems or inline measurement tools instead of manual inspections.
Myth #3: More Machining Equals Higher Precision
🔹 The Belief: The more machining a part undergoes, the more precise and reliable it will be.
🔹 The Reality: Over-machining increases cycle times and material waste while often offering no real performance advantage.
🔹 Example: A stamped metal bracket was originally designed to be CNC-machined for added precision. However, engineers redesigned the part for progressive stamping instead.
The result?
✅ Production time reduced from minutes to seconds per part
✅ Material waste significantly lowered
✅ Part precision remained within functional tolerances
💡 The Fix:
✅ Consider high-precision stamping, forming, or laser cutting instead of over-relying on machining.
✅ Evaluate cost vs. precision needs—if stamping or forming meets requirements, machining may be unnecessary.
✅ Reduce machining steps by optimizing initial tooling designs.
Final Thoughts: Efficiency Starts With Smarter Manufacturing Decisions
Many long-standing precision manufacturing practices are based on outdated assumptions—and they could be slowing down production instead of improving it.
By optimizing tolerances, minimizing unnecessary secondary operations, and reducing over-machining, manufacturers can:
✔️ Speed up production while maintaining quality
✔️ Reduce costs and minimize material waste
✔️ Improve overall process efficiency
The key to better manufacturing isn’t doing more—it’s doing what actually works.
Gromax Precision Die & Mfg., Inc. specializes in designing and manufacturing precision metal stamped parts and tooling, including progressive stamping dies and custom equipment. With an on-time delivery rate of 99.68% and a defect rate of just 0.066%, the company ensures exceptional reliability and quality.
Gromax is ISO 9001:2015 certified and ITAR registered, serving industries such as medical, defense, aerospace, industrial automation, and automotive with high-quality, innovative solutions.