Creating a cell manufacturing layout at its Post Falls, Idaho, headquarters represented a key component of Buck Knives' lean integration. The new process sharpened the flow of materials to top efficiency. Fabrication begins when fine blank machines process lower-grade steel with specifically shaped dies at a rate of 1,000 units per hour. Buck sources raw metal from AK Steel in Ohio, and imports sanding steel from Sweden. A laser machine is used for higher-grade material, and scraps are melted down and recycled off-site.
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