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Conference

Management

F069: From Chaos to Control: Disciplined Margin-Protecting Processes

  • Date

  • Time

  • Experience Level

    Intermediate

  • Location

    N227-228

Presentations

Operational Discipline in a Volatile Market: How Fabricators Protect Margins Without Disrupting Production

9:00 am – 9:30 am Intermediate

Metal fabricators are entering 2026 with more stable operations than in recent years, yet many continue to experience margin erosion despite steady volumes and improved delivery performance. The challenge is no longer disruption—it is the accumulation of embedded and poorly governed costs that quietly drain profitability.

This session examines how fabrication cost structures have evolved following years of supply chain volatility, labor inflation, and trade uncertainty. Using real-world fabrication environments, the presentation highlights where cost typically hides today—across freight and logistics, material specifications, services, maintenance, energy, and internal decision-making—and why traditional sourcing and budgeting approaches often miss these drivers.

Attendees will learn how leading fabricators are shifting from a narrow focus on throughput to total cost ownership and execution discipline. Practical frameworks will be shared for improving cost transparency, aligning operations and finance, and sustaining savings without disrupting production or customer commitments.


Stop Improving Everything: How to Manage Your Processes and Make Fabrication Predictable Again

9:30 am – 10:30 am Intermediate

If you run a fabrication or machine shop, you’ve felt the squeeze:

  • Hiring and keeping skilled people
  • Managing capacity, backlog, and delivery
  • Making equipment and automation investments actually pay off

But here’s the hard truth:

  • Great people can’t shine inside a broken system.
  • Delivery becomes whack-a-mole when you rely on workarounds and heroics.
  • New tech/automation won’t fix late shipments.

Small shops don’t fail because they lack effort. They struggle because they lack stability.

Stability comes from standards. And that drives predictable lead times, better schedule attainment, faster changeovers, higher throughput.

In this session, you’ll learn a practical Business Management System with three repeatable elements:

    • A “focus filter” for leaders: what to improve vs. what to ignore this quarter
    • A method to make improvements and involve your people to boost performance
    • A lightweight morning meeting outline to align your team, clear the noise, and protect your capacity

About the Speakers

  • Ranjan Bhattacharjee

    ERA Group

    Biography

    Ranjan Bhattacharjee is an operations and transformation executive with more than 30 years of experience improving profitability, productivity, and supply chain performance across manufacturing and fabrication businesses. He has led turnarounds, operational transformations, and growth initiatives across more than 70 manufacturing locations in North America, including roles with private equity-backed, public, and family-owned companies. Throughout his career, Ranjan has helped organizations improve cost visibility, strengthen execution discipline, reduce complexity, and expand margins. He brings a practical operator's perspective on how cost structures evolve and how leading manufacturers sustain performance in changing market conditions.

    More Details about Ranjan

  • Chad Bareither

    Bareither Group Consulting

    Biography

    Chad is the principal consultant at Bareither Group Consulting. His approach leverages 20+ years of experience in continuous improvement to enable change for transformational results. From mid-market manufacturers to fortune 500 companies, Chad and his team apply Lean and Six Sigma methods in a strcutred framework to acheive results and develop your team. Chad is a certified Lean Six Sigma Master Black Belt and holds a Masters Degree in Industrial Engineering. He and his wife reside in Southwest Michigan with their three children, but engagements have taken him across the country and the world.

    More Details about Chad

Pricing & Registration

Early-Bird Pricing
Through September 11

Price
Individual Sessions $220 $175
Workshops $600 $480
Full Conference (5-10 Sessions) $900 $720

Price
1 Session $125
2 Sessions $225
3 Sessions $300
4-8 Sessions $450

Early-Bird Pricing
Through September 11

Price
Weld-Ed Conference $75 $50
One-Hour Sessions FREE
90-Minute Sessions $200 $150
Half-Day Sessions $550 $450
Full-Day Sessions $600 $500
Professional Program $425 $325

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