Expanding Capacity at Ripley Machine — Part 2
Continuing our commitment to capability, quality, and customer satisfaction
At Ripley Machine & Tool Company, our previous post, Expanding Capacity at Ripley Machine, shared how we invested in new equipment and expanded our machining capabilities.
Since then, we’ve focused on taking those investments to the next level — turning added capacity into better quality, faster response, and higher customer satisfaction. Here’s how we’ve made that happen.
1. Building on a Strong Quality Foundation
Building on our ISO 9001:2015 foundation, we are advancing our Quality Management System (QMS) toward AS9100 standards. Even before certification, these improvements are helping us strengthen consistency, documentation, and quality across our operations.
We completely overhauled our QMS from the ground up to ensure that our team members have clear, consistent, and accessible processes. Together, we wrote hundreds of detailed, task-level instructions — everything from setup procedures and gaging methods to inspection routines and documentation steps.
These written, visual, and digital tasks have transformed the way our operators work:
Less time asking questions – because the answers are available right where they need them.
More consistency across shifts and setups – ensuring every part meets the same exacting standard.
Fewer mistakes and less scrap – which reduces costs for our customers and increases throughput for everyone.
We also built a new quality room, a dedicated and climate-controlled area that streamlines our inspection and documentation process. It’s another step in our ongoing commitment to excellence — a continuation of what we shared in Ripley Machine Doubles Down on Quality.
2. Smarter Tooling = Faster Setups
Setup time can make or break a machining operation. To support our expanding capacity, we implemented a new tooling system designed to standardize and expedite setups across machines.
As we highlighted in Taking Control of Our Tooling, this system gives our machinists quick access to properly maintained and organized tools, preset with the right offsets and ready to run.
The results have been immediate:
Setup times have dropped significantly.
We’ve improved repeatability between runs.
Operators spend more time cutting parts — not chasing tools.
All of this contributes to higher spindle utilization and faster delivery for our customers.
3. Real-Time Scheduling and Adaptability
To stay responsive to our customers’ changing needs, we’ve begun fully utilizing the scheduling module in ProShop ERP. This gives us real-time visibility into our entire production floor — machines, jobs, setups, and staffing.
When a customer needs a rush order, or a delivery date shifts, we can re-prioritize jobs instantly and see the impact across the schedule. It also helps us identify potential bottlenecks before they become problems, keeping throughput steady and predictable.
4. Daily Drumbeat: Communication that Drives Continuous Improvement
Every morning, our entire team gathers for a quick “Daily Drumbeat” meeting — a short but powerful ritual that keeps Ripley Machine aligned, focused, and improving every single day.
These meetings are more than just a status check. Yes, we review hot and rush orders, track jobs and machines running behind schedule, and identify bottlenecks that need attention — but that’s only part of what makes the Drumbeat so valuable.
Each session also reinforces the foundations that drive our culture and performance:
Quality Management System (QMS) — We talk about quality every day. Whether it’s reviewing recent inspection findings, discussing a nonconformance, or celebrating a successful audit, our team stays engaged in maintaining and improving our system.
Safety First — If there’s a safety concern or observation, we bring it up immediately. Everyone has a voice, and everyone is responsible for a safe workplace.
Team Connection — We use the Drumbeat to share updates, celebrate milestones, and recognize one another. It keeps our communication human and our culture strong.
Lean Thinking — Every employee at Ripley Machine can name and explain the 6S’s and the 8 wastes — and more importantly, how they apply to our shop. We actively discuss where we see waste, how to eliminate it, and how to keep our workspace organized and efficient.
The result? A shop floor that’s informed, engaged, and empowered. Our people understand how their work connects to the bigger picture — quality, delivery, and customer satisfaction.
The Daily Drumbeat has truly become the heartbeat of our company, fueling communication, safety, accountability, and continuous improvement.
5. A Relentless Focus on Customer Service
At the end of the day, all these systems and processes mean nothing without one constant: our dedication to customer service.
As we’ve shared before — and as emphasized in MakingChips’ The Secret to Happy Customers — our approach is built on listening, transparency, and responsiveness.
We don’t just machine parts; we build partnerships. That means:
Clear communication about lead times and progress.
Flexibility when your schedule changes.
Accountability for cost, quality, and delivery.
Every improvement we make — from AS9100 to tooling to scheduling — is designed to deliver a better experience for our customers.
6. What’s Next
We’re not done yet. Our focus for the coming year includes:
Completing AS9100 certification and expanding into new markets that demand higher levels of documentation and traceability.
Continuing to develop our team training so every employee understands the “why” behind our processes.
Leveraging data from ProShop to improve planning accuracy and further reduce lead times.
Exploring new automation and process-control tools to maximize our uptime.
At Ripley Machine & Tool Company, we don’t just want to grow in size — we want to grow in excellence. Every new system, process, and improvement moves us closer to that goal.
Ready to See the Difference?
If you’re looking for a machining partner who combines precision, responsiveness, and true customer care, we’d love to show you what Ripley Machine can do.
Contact us today or send us your drawing to get started.
