Case Study: How Openex Delivered 65 Custom Atmospheric Mixing Tanks Through Process Optimization

Project Overview

Openex Metal Fabrication recently completed the batch production and delivery of 65 custom atmospheric mixing tanks featuring internal layered structures. These tanks were precision-engineered supporting components with demanding dimensional and quality requirements.

To meet the project’s production schedule without compromising quality, Openex coordinated its planning, production, process engineering, and quality inspection teams. The project combined standardized production-line operations, specialized process adjustments, differentiated welding procedures, and systematic quality control.

The result was the successful delivery of all 65 tanks on schedule and in accordance with the project’s quality requirements.

Project at a Glance

1. The Challenge: Producing 65 Custom Tanks Consistently

Batch manufacturing of custom industrial tanks requires more than repeating the same fabrication steps. Each stage must be coordinated to maintain dimensional consistency, welding quality, and reliable sealing performance across the entire production run.

For this project, Openex faced several important manufacturing challenges.

Maintaining Consistent Quality Across the Batch

The 65 tanks required close control of dimensional accuracy and fabrication quality. Production needed to proceed efficiently while ensuring that welding deformation, dimensional deviations, and potential leakage did not compromise the finished products.

Adapting Processes to Short Tank Bodies

The relatively short tank bodies could not be accommodated by conventional equipment configurations. The production team therefore needed a project-specific manufacturing approach rather than relying entirely on standard procedures.

Balancing Welding Quality and Production Efficiency

Different weld locations had different load-bearing and sealing requirements. A uniform welding approach would not adequately address every joint’s functional requirements, so the team developed differentiated composite welding procedures to balance precision, strength, and production efficiency.

Coordinating Multiple Production Departments

With multiple manufacturing stages and 65 units to complete, effective scheduling and communication were essential. Business, production, process engineering, quality inspection, and production planning teams worked together to keep the workflow aligned and resolve issues as they arose.

2. The Manufacturing Solution: A Standardized End-to-End Workflow

Openex organized the project into a coordinated production sequence, breaking the manufacturing process into six principal stages:

1. Material cutting
2. Edge planing
3. Plate rolling
4. Tank assembly
5. Composite welding
6. Water testing

This workflow established clear production stages and helped the team coordinate work between operations. Standardized procedures reduced avoidable process variation, while project-specific adjustments addressed the equipment and fabrication requirements of the short tank bodies.

Step 1: Material Cutting

The cutting stage prepared the required workpieces for subsequent forming and assembly operations.

Accurate preparation was important because dimensional errors at the beginning of the process could affect plate forming, fit-up, welding, and final tank geometry. Openex incorporated dimensional control into the production workflow to help prevent upstream deviations from carrying into later stages.

Step 2: Edge Planing

Edge preparation was carried out before assembly and welding.

This stage helped prepare the joint edges for the required welding operations. Consistent preparation was important for achieving suitable joint fit-up and supporting the quality requirements of the subsequent welding process.

Step 3: Plate Rolling

The prepared plates were rolled to form the tank bodies.

Plate forming required coordination with the preceding cutting and edge-preparation stages. The production team managed the workflow to support the required tank geometry and minimize dimensional deviations before assembly.

Step 4: Assembly

The formed components were assembled before welding.

During assembly, dimensional accuracy and component fit-up were important control points. The team followed project-specific operating requirements to help maintain consistency and prepare the tanks for the next manufacturing stage.

The assembly process was also adapted to accommodate the short tank bodies that could not be handled through conventional equipment arrangements.

Step 5: Composite Welding

Welding was one of the project’s most important technical control points.

Instead of applying an identical welding approach to every joint, the team selected differentiated composite welding procedures according to the welds’ load-bearing and sealing requirements.

This approach was designed to balance three key objectives:

• Dimensional control: Manage welding deformation and help maintain the required geometry.
• Joint integrity: Address the strength requirements of the relevant welded connections.
• Sealing performance: Control weld quality in areas where leak prevention was important.

The team also refined the manufacturing sequence, improved tooling arrangements, and clarified operating procedures to address the constraints associated with the short tank bodies.

These adjustments helped the production team adapt its methods to the actual workpieces rather than forcing the project into an unsuitable standard setup.

Step 6: Water Testing

Water testing was included as a dedicated stage in the manufacturing workflow to evaluate tank sealing performance.

This step provided a practical quality-control checkpoint for identifying potential leakage before delivery. Together with dimensional inspection and welding-quality controls, it helped the team address the project’s principal risks.

The specific test pressure, duration, acceptance criteria, and inspection records were governed by the project requirements; these details were not included in the available project information.

3. Solving the Short-Tank Manufacturing Problem

One of the project’s most significant challenges was that the short tank bodies could not be accommodated by conventional equipment arrangements.

Rather than allowing this constraint to disrupt the production schedule, Openex developed a dedicated process solution.

The team took three main actions:

Adjusted the manufacturing sequence. The production flow was reviewed and modified to suit the workpiece geometry and the practical requirements of each operation.

Improved tooling arrangements. The team adapted the tooling setup to better accommodate the short tank bodies and support stable fabrication operations.

Refined operating procedures. Detailed work instructions were clarified to help operators execute the adjusted process consistently.

This approach illustrates an important principle in custom metal fabrication: standard production methods provide a foundation, but non-standard components may require engineering adjustments to equipment arrangements, tooling, and process sequencing.

For industrial buyers, the ability to recognize these constraints early and develop a practical manufacturing response can be as important as the equipment itself.

4. Quality Assurance Throughout Production

Openex controlled quality throughout the manufacturing process rather than relying exclusively on final inspection.

The team focused on three primary risk areas.

Cross-Functional Quality Coordination

The project’s quality objectives depended on cooperation between several departments.

• Production planning coordinated the schedule and manufacturing sequence.
• Process engineering developed adjustments for the short tank bodies and refined production procedures.
• Production teams carried out the standardized operations and followed the revised work instructions.
• Quality inspection monitored dimensional accuracy, welding quality, and sealing performance.
• Business and project coordination teams helped maintain communication around delivery requirements.

This cross-functional approach helped the team identify risks earlier, manage issues during production, and maintain control over the batch manufacturing process.

5. The Results: 65 Tanks Delivered on Schedule

Openex completed the batch delivery of all 65 custom atmospheric mixing tanks on schedule, meeting the project’s quality requirements.

The main outcomes were:

• Successful batch delivery: All 65 tanks were completed and delivered as planned.
• Standardized production: The six-stage workflow provided a structured approach to coordinating multiple manufacturing operations.
• Process adaptability: Dedicated tooling and process adjustments addressed the manufacturing constraints associated with short tank bodies.
• Controlled fabrication quality: Dimensional accuracy, welding quality, and sealing performance remained central throughout production.
• Improved production management: Early risk assessment, ongoing process control, and process refinement strengthened the team’s approach to similar non-standard manufacturing projects.

The project also provided further experience in serving non-standard operating conditions and reinforced the importance of combining production planning, process engineering, and quality management in batch fabrication.

6. What This Project Demonstrates About Openex

This project demonstrates Openex Metal Fabrication’s approach to manufacturing custom industrial equipment components: establish a clear production plan, adapt processes to the actual workpiece, and apply quality controls throughout the manufacturing sequence.

For customers sourcing custom tanks and other fabricated components, several capabilities are particularly relevant.

Batch production planning: A coordinated workflow can help manage multiple units while maintaining production consistency.

Process engineering and optimization: Non-standard geometries may require tailored tooling, revised sequencing, and more detailed operating procedures.

Welding process control: Welding methods should be selected with the joint’s functional requirements, dimensional constraints, and sealing needs in mind.

Process-based quality assurance: Dimensional inspection, welding-quality controls, and sealing tests can be integrated into the manufacturing workflow to address key risks before delivery.

Cross-department coordination: Planning, engineering, production, and quality teams need to work together to manage schedule and quality requirements.

The same principles can support other custom fabrication projects in which production volume, non-standard geometry, welding requirements, and delivery deadlines must be managed together.

7. Looking for a Custom Metal Fabrication Partner?

Whether your project involves custom tanks, welded assemblies, structural components, or other non-standard fabricated products, selecting a supplier with the right process-planning and quality-control capabilities is essential.

Openex Metal Fabrication works with industrial customers on custom metal fabrication and heavy manufacturing projects. Share your drawings, specifications, target quantity, material requirements, and delivery schedule with our team to discuss manufacturing feasibility and project requirements.

Ready to discuss your project?

• Request a quotation: Contact Openex Metal Fabrication
• Explore our manufacturing capabilities: Metal Fabrication Services
• Learn about our machining capabilities: CNC Machining Services

When contacting us, include available engineering drawings, required quantities, material specifications, dimensional tolerances, inspection requirements, and your target delivery date. These details help our team evaluate your project more efficiently.