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Robotic Welding: What companies do need it and how to set it up

Robotic Welding: What companies do need it and how to set it up

Robotic welding has really taken place in manufacturing companies.

By 2016 there were more than 250,000 welding robots around the world. The countries that use robotic welding the most are Japan, China and the United States of America, in that order.

But to get started with this topic, let’s define what is robotic welding.

What is robotic welding

To start, let’s define robotic welding. We can say that robotic welding is the use of mechanical tools capable of being programmed (robots) to perform welding processes in an automated way.

These processes should include both welding the pieces and moving them.

Using an example, let’s see how extensive robotic welding is. Of the approximately 120,000 robots in the United States by 2005, half were used for welding processes.

Ten years later, the trend is similar. This makes it clear that welding is by far the most used application by robotics.

When welding is robotic

When a human operator participates directly in the welding process, as sometimes happens with the GMAW, we cannot say that it is purely robotic welding.

If a human operator participates in operation with a robot, under established and controlled safety conditions, we are in the presence of a Collaborative System. These systems are called Collaborating Robots.

Now, spot welding and large-scale arc welding that is done in automobile manufacturing is in fact robotic welding.

Robotic Welding: What companies do need it and how to set it up
Many companies can benefit from robotic welding

Who uses robotic welding

Welding robots have been used mainly by large manufacturing companies, with the automotive being the main one.

Secondly, we can include large to medium-sized companies that manufacture products or spare parts, again, for the automotive company.

Medium to small companies rarely or never would use welding robots in their processes.

It is evident that the costs that welding robots would use to have had a lot of weight for the company.

However, the trend is changing. As always, technology gets a lower price as is established in the market.

In addition, more diverse welding robot systems, including portable ones, have been created that meet more particular needs.

Today, both medium and small industries can use welding robots with only a small investment.

The origin of robotics in welding

In the United States, they started making robots in the 60s of the 20th century. However, its application to welding began about 20 years later.

At that time the automobile industry began to use spot welding to manufacture vehicles, for which it employed robots.

At first, the use of robotic welding was very basic, but given its effectiveness, it soon began to be applied for more processes.

Today, only robotic arc welding takes 20% of industrial automated welding applications.

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Processes that can be done with robotic welding

With robotic welding, arc welding can now be done in GMAW, GTAW and Plasma, spot welding, sheave welding and laser welding.

The fact that robotic welding can be used for more processes or in different circumstances will motivate more companies to obtain some welding robots.

These improvements will only serve to increase the speed or quality with which they produce.

The shortage of operators

It is also true that it will be increasingly difficult to get operators who are properly trained for professional welding jobs.

The AWS (American Welding Society) has calculated that by 2020 there will be a shortage of 290,000 professional welders in the United States.

Similar scenarios can be expected in other countries.

On the other hand, the health and safety of operators is something that must also be taken into account.

When welding gases are emitted that are harmful to health. This issue will be explained later in this article.

Effectiveness and efficiency are also key factors whereby a company may need robotic welding.

In fact, they are essential to produce high-quality products and improve the price to the public.

Given these criteria, more and more companies should consider including robotic welding in their manufacturing processes.

When welding robots are necessary

A company should consider the possibility of including welding robots in its processes if one or more of the following points identify its operation:

  • They need to increase production
  • They need to reduce operating costs
  • There are jobs for which they don’t get staff
  • They need to improve the quality
  • They need to complete jobs consistently
  • Some jobs are very difficult to do manually
  • Some jobs are or can be dangerous or polluting for operators

With respect to these points, reducing operating costs is something constant in all companies, no matter where they are.

So all of them should use welding robots to improve their costs in the medium and long term.

Robotic Welding: What companies do need it and how to set it up
There are many reasons for having welding robots in the company

Equipment for robotic welding

When the matter about the equipment necessary for robotic welding is brought out, it immediately comes to the minds of those responsible in companies that are very expensive machines.

Although some are still expensive today, as has happened with computers and personal devices, technologies have dropped in price over time.

This has made it possible for smaller companies to have been able to obtain robotic welding equipment and are benefiting from having reduced their costs.

This trend, known as the “Moore’s Law” will continue. It is expected that manufacturers produce new models more specialized and at a lower price.

Another common idea is that they are very specialized equipment and it will be very difficult or unpayable to have trained personnel to handle it.

But in fact, welding robots are not usually that complex. The training required for the operation of a robot is divided into 2 parts.

A part of the training is for the operator who loads and unloads the material to be welded. Only a few minutes of training may be necessary.

The other part is the robot programmer training. This will take between a few hours or a few days depending on your welding experience and whether or not you will use virtual programming software.

An example of a welding robot

Ideally, the person in charge should have knowledge of welding processes, in order to confirm that the job has been well done.

It is also ideal that this person knows or has some idea of how to run a program. So logical thinking is ideal for this type of work.

Most robotic welding systems have several aspects in common, regardless of the application for which they will be used.

So, someone who has been trained to program a welding robot most likely will be able to handle a different one in a short time.

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Parts of a welding robot

Basically a welding robot is composed of 3 main parts and some other secondary parts.

The main part is a manipulator or “arm.”

This is the part of the machine that repeats movements with high precision in their respective 6 to 7 axes to bring the torch to a position to execute the welding.

The second component is the controller. This coordinates the movements of the axes of the arm and is the central computer of the system.

Some have PLC capabilities included being able to coordinate many alternate tasks to the robot’s movement.

The operator sends instructions to the controller through a program that he creates in the command/teaching panel (also known as Teach Pendant).

The third basic component is the welding power source. It receives a configuration from the controller for each welding bead that the manipulator or “arm” performs.

Robotic Welding: What companies do need it and how to set it up
The tech pendant is one of the main parts of a welding robot

Some of the other common parts in welding robots are

  • Sensors
  • Cables
  • Communication devices
  • Interfaces
  • Nozzle cleaners with wire cutters
  • Positioning systems such as horizontal or vertical two-axis rotators

These positioners allow the piece to be adjusted in the best possible welding position.

The positioners can become medium or large structures that help improve the productivity of the robot and the operators for loading and unloading materials to be welded.

Choose the welding robot from the best brand

Although there are several brands that produce welding robots, we have proven that the ones from OTC Daihen are the best value on the field.

The companies that have implemented them have benefited from the total integration in a single native language of all its components (Manipulator, Control, Welding Source, and Positioners)

This has allowed the easiest programming of the robot in the arc welding processes of the market.

Robotic Welding: What companies do need it and how to set it up

We have successfully installed several of the welding robot models of the OTC Daihen to different clients in South America.

In the video, you can see this one of these robots in action. 

Of course, each manufacturing plant has its own needs and, based on that, we recommend which welding robot would be appropriate.

In any case, we invite you to contact us for advice.

The human side of automation

It is almost impossible, when it comes to automation in the company, that operators do not feel fear for their jobs.

It is common for some to feel contempt, and even try to sabotage the implementation of robotic welding in the company, in order to avoid losing their jobs.

However, the vast majority of companies that implement automated welding in their processes do not do so to fire personnel, but to expand their production.

Often the staff is transferred to other areas where their capabilities can be used.

In fact, automation generates new jobs, because, in every place where there is a welding robot, someone will need to program and control it.

But this factor is not evident for most operators. That is why they have a negative perspective.

For companies that are going to take the step to automation, they are recommended to provide information to their staff.

For many, it is important to know that a machine is not going to take away their job.

Perhaps the opportunity can be taken to promote productivity among plant personnel.

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About the health of the operators

It is evident that increasing productivity through welding robots will also increase the number of gases emitted during operation.

This increase in pollution can be prevented from affecting the health of employees by placing smoke extraction systems near the cells of welding robots.

Of course, the company that provides robotic welding equipment must be able to help you plan these matters.

When we install automated welding in a plant, we previously visited it to know its current situation and what they want to achieve.

This allows us to design a tailored solution that meets their needs.

The clamping device (JIG)

In most robot welding applications, the clamping device is considered the most important component for a successful implementation.

This auxiliary equipment receives the parts to be welded from the operator and adjusts them with high precision to ensure a position in the three coordinates consistently.

In this way, the welding robot will be able to accurately make the same welding bead from start and end, welding after welding.

The characteristics of the parts to be placed in the clamping device (JIG) must always be the same.

The length, height, thicknesses, angles, arcs, folds and other geometries must always be consistent to ensure that the JIG positions the set of parts to be welded correctly.

Robotic Welding: What companies do need it and how to set it up
The clamping device (JIG)

To successfully develop the clamping device (JIG) companies have 2 options: If they have an engineering department, they can design the shape and mechanism of this component.

Otherwise, the supplier of the welding robot, like our company, can provide the JIGS design and manufacturing service, according to the client’s application.

How to implement robotic welding in your company

Implementing automated welding processes in the company is not an activity that is done in one day.

On the contrary, even in plants where welding is an integral part of production processes, this change to automation can take up to a year.

The key to implementing robotic welding successfully in the company is to keep it as simple as possible and that this covers all or most of the repetitive processes of the operation.

To explain it better: Suppose that a production line is divided into 4 sections, of which 1 is very complicated and requires custom welding while the other 3 are constant and unchanged processes.

The section that can vary, due to the welding that must be customized can be done by an operator.

The other 3 sections, composed of repetitive processes, can be perfectly completed by a welding robot.

The welding performed by the robot is indicated through a program. To improve the efficiency of the robot, the idea is to run the same program for a long period of time, instead of constantly changing the program.

Some companies even prefer that a welding robot perform a single program and obtain another that performs another operation. That way they never stop them.

Another issue to take into account is the number of movements that the robot must make and the heat that the welding produces in the piece.

The welding robot operator

The ideal person to handle the robot must be someone who knows how to weld and has knowledge of how to program any CNC type machine.

Even if it is not going to program in G code, experience gives you the notion of step-by-step programming logic of welding operations.

Whether or not it has been a welding operator is important when it comes to seeing problems that have been caused in the parts welded by the robot.

If this person has no idea of ​​welding, he will not know what the problem may be.

An expert welder, meanwhile, seeing a wrong result of a welded part, can determine which of the many factors that may be affecting the robot.

However, the skilled welder may also have the tendency to always do manual welding and not use a machine that replaces his work.

This makes it a challenge for the company to find the right person to do this job.

Robotic Welding: What companies do need it and how to set it up
The welding robot operator must have welding knowledge

Having notions of how a device can be programmed to perform an action is of course very useful as well.

However, most of the time this particular training is provided by the company that advises and sells robotic welding equipment.

One of the most important skills that the selected person must have is the ability to remain focused, see details and recognize patterns.

For example, if one of the pieces was not well welded, even a small detail, it could be because it was not well placed in the position where it should go.

But if the next one is also bad, it may be something else.

In cases like these it is better to momentarily stop the operation and correct the error.

Finally, the designated operator must also be able to carry out a preventive maintenance program for the welding robot.

This will help prevent major arrests and expenses for unforeseen repairs.

Robot welding has many advantages

If well implemented, robotic welding can exponentially increase the productive capacity of any company.

This could mean a greater quantity of products for sale, with possibly the same number of personnel.

Although there is no standard, the return on investment by a welding robot is usually 12 to 15 months.

But the life of robotic welding equipment is much longer. This could increase the company’s income or lower product prices.

So, in general, robotic welding leads companies to be more competitive, cover more markets and improve their revenues. More than enough reasons to implement it in your company.

We want and can help you define what is the robotic welding equipment you need for your operation. Contact us at any time to receive more information.

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Reducing welding costs: 5 effective methods for companies

Reducing welding costs: 5 effective methods for companies and contractors

Reducing welding costs is a formidable way to improve companies revenues. This could allow to give better prices and getting more customers. As well, companies could be able to improve their employees benefits. So, reduce costs could make a difference in companies growth and expansion plans.

In this article we are going to explain 5 ways to reach it. 3 of them are related to planning carefully your work. The fourth is about the job execution. Finally, there is an explanation about a constant activity every company ought to be doing.

So, let’s get started.

1) Choose the appropriate welding equipment

Although there may be great similarities, there are no 2 factories alike. For this reason, the equipment used for the processes of welding can vary according to the needs that each one has, even within the same group of products.

For example, more than 5,000 welding points are required to manufacture a vehicle. In these cases, automation, by means of welding robots is imperative. In very general figures it could be said that 80% of this welding is by means of robots.

However, for the construction of ships, the process is almost the reverse. Manual welding occupies almost 80% of the job.

In both cases, companies must ensure that they have the best equipment for the type of welding they need, be manual or automated by robots.

Many manufacturers of welding equipment and consumables are constantly developing systems and technologies in order to make equipments more effective and efficient, resulting in lower manufacturing costs.

It is a good idea for companies to include in their costs the periodic updating of welding equipment, for these new technologies soon benefit the company.

Miller offers a new technology called Arc Reach, applicable in sectors of construction, assembly of structures, shipyards, among others.

Miller Arc Reach technology

Miller has recently included Arc Reach technology in most of his welding equipment. With this system the operators can remotely adjust the welding parameters without a control cable.

This saves many comings and goings to and from the power source, which can be done several times a day and take many minutes.

It is estimated that the ArcReach technology prevents the loss of about 250 hours/year per welding operator (time saving).

In some countries, such as the United States, labor payment to welding operators can represent 80% of the work costs. In places like these, it is particularly important to apply these new technologies.

Miller Arc Reach technology
Miller Arc Reach Technology

In other countries, labor may not represent so much of the work costs, but still, increase operators production through, for example, Arc Reach technology, can make the works come to an end sooner and more jobs or products could be made in a year period, increasing billing.

Of course, if the welding equipment of the company is more than 5 years old, they are not enjoying these improvements. That is why periodic investment in welding equipment is an excellent way to reduce costs.

These welding equipment become assets for the company, which help them achieve more or better in less time.

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2) Choose the right welding consumables

Just as it is necessary to constantly invest in state-of-the-art welding equipment, the consumables that are going to be used must be of good quality.

This is an issue in which many companies choose to save money. “After all, the consumable is something that should be consumed”, some reason.

Although this idea is clear true, the manner and time it takes to consume can reduce welding costs or do not.

It is important that these parts are able to withstand excessive heat or long duration. Generally, the heat of the welding application shortens the life of consumables.

In some countries welding accessories and consumables can represent 80% of the total cost of work or production.

When buying consumables, it is especially important to take care of the quality of:

  • Contact Points
  • Nozzles
  • Gas diffusers

Contact tips: The ones of good quality resist better wear due to electrical erosion, high temperatures, abrasion and slag accumulation.

Choose the right welding consumables
Choose the right welding consumables

Tregaskiss offers some technologies that help reduce costs in consumables.

Tregaskiss TOUGH LOCK contact tips are precision machined to ensure exact tolerances and a finish of the upper hole resulting in constant welding quality and performance.

With a double conductor thread design, the tips can be rotated 180 degrees to create a new wear position and prolong the life of the tip.

TOUGH LOCK contact tips also work at cooler temperatures than many others, which reduces wear and minimizes downtime for the change.

Nozzles: It is ideal to buy those that have a surface as smooth as possible, to be sure that they have gone through rigorous quality controls.

Gas diffusers: Avoid buying gas diffusers with gaps outside the circumference, as these could alter the way of how the shielding gas comes out, causing a negative impact on the quality of the weld.

All consumables can be affected by splash. Although we will talk about the splash later, it is good to leave clear that the consumables of low quality usually produce more splash than the others.

Quality consumables help reduce welding costs, because they have a longer duration, which minimizes the consecutive purchase of pieces and the time lost in changing them.

At the same time, good quality welding consumables come clean and free of factory grease, which increases their useful life.

On the other hand, even when all are of good quality, it is necessary to choose the appropriate consumable for each operation. If there is a person or purchasing team, they must be able to plan the consumables required to not stop the work or production.

Buying based on quality and not on price can be a considerable way to reduce the medium and long term welding costs.

What is an inverter welding machine?

They are welding equipment that uses an electronic board or chip instead of a transformer to convert the alternating current into direct current.

The operating principle of the inverter for welding is that the frequency of 50-60 Hz of the alternating current that comes from the electrical network increases considerably, between 20,000 Hz and 50,000 Hz.

A higher frequency implies the use of a smaller transformer, which allows the manufacture of smaller and lighter energy sources.

What are the advantages of using an inverter welding machine?

Due to the change in their internal components, inverting welding machines are, on average, 3 times lighter and smaller than traditional machines. This allows the operators to work in heights or places of difficult access.

Since they provide continuous current, inverting welding machines can use any type of electrodes. They can be used for all types of arc welding. In addition, there are single-phase and three-phase models.

Good penetration and stability of the arch is guaranteed with the use of inverting welding machines. This is due to the continuous control of the properties of the arc, even when the voltage is unstable or weak.

They also consume less energy than their peers with transformer-only technology. Lower amount of energy represents savings in operating costs.

What is an inverter welding machine

3) Teach and train operators

Henry Ford, who started the company that bears his last name and had to deal with welding issues, once said: “There is only one thing more expensive than training a worker and let him go: do not train him and let him stay.”

Certainly, if operators are not experts in what they do, they can make mistakes that, at less, increase the production cost of the companies.

Teaching (giving theoretical instruction) helps an operator adapt more quickly to a new technology. Training (giving practical instruction) develops your ability to do it.

When the personnel is not well trained, they may even have accidents that could end up in the detention of the work or the factory, demands, huge losses, etc.

Training staff can make them more experts in certain welding processes. This could be good for the company, because an expert in a certain welding process could do much faster those jobs that he masters perfectly than any other operator.

If the company has well-trained personnel, each in different welding processes, it could make the production line more efficient.

Of course, something in which all operators -and all the company’s staff- should receive training is about safety standards.

Teach and train operators

4) Prepare the surfaces and weld with precision

Alexander Graham Bell, an English scientist, used to say: “Before anything else, preparation is the key to success”. This is certainly necessary to reduce welding costs.

One of the best ways to achieve this is to optimize the preparation of the pieces to be welded. In some cases, depending on the thickness of the material, although it may take slightly more time, it is advisable to make a double beveling to the pieces to be welded. That way you could save on welding consumables.

 

Cleaning the parts thoroughly, eliminating oxidation, paint residues, grease, oil, and moisture, can help the resulting weld to be free of pores and welded at an ideal speed for the process.

Part of the preparation may include taking care of consumables such as wires and electrodes. If some of these are left at the end of the workday, they should be carefully stored to prevent them from getting wet or filled with grease or other contaminants.

There is a lot to be said when it comes to improving welding operations. Here we only list some points:

"Before anything else, preparation is the key to success"

Consider including welding automation processes

A welding robot can spend 85% of the time welding while an operator usually spends only 20%. Only this figure manages to reduce welding costs considerably in a short time.

It is clear that, however advanced they are, welding robots need humans to program and assist them. There are consumables to replace and situations to attend to.

In addition to the time and money saved with automated welding, it is also possible to improve the quality of processes and minimize the time that work is stopped.

Welding robots usually complete the processes so that reworking is not necessary. This is another saving in time and money.

When welding robots are used, it is necessary to carefully monitor these issues:

  • Add accessories and peripherals that improve work
  • Manage consumables properly and take care of them
  • Do preventive maintenance (PM)
  • Use optimal welding consumables and calculate their duration

However, installing welding robots in a company can mean a large investment. In the long run, however, savings can be seen in times of production and quality of the pieces produced.

To automate some of the welding work, companies require experts to advise them on which equipment to buy and how to use them. Our experts can help you install the welding robots that your particular production needs, with the best cost-benefit ratio.

Of course, not all operations can have automated welding. Some companies carry out field work where manual welding is essential.

We have offices in the United States, Colombia, Brazil and Venezuela. We sell and ship to more than 90 countries, including Argentina, Belize, Brazil, Bolivia, Colombia, Costa Rica, Chile, Ecuador, Guatemala, Guyana, French Guiana, Honduras, Mexico, Nicaragua, Panama, Paraguay, Peru, Suriname , Uruguay, Venezuela and the Caribbean.

The splash

In particular with manual welding it is necessary to avoid splashing. Although some spatters may not affect the strength of the weld, they increase cleaning costs.

It is possible that the splash is caused by:

  • Having a very high current
  • Having a not appropriate current for the size or type of electrode in use
  • The correct polarity is not being used
  • The arch is very wide
  • The correct angle is not being used
  • The electrode is wet

To reduce splash, try to correct any of these possible errors.

Speed up taking care of quality

Examine the welding processes that are carried out in order to see if they can be improved. Issues such as the diameter of the wire or electrode, the speed of the feeder, the type of gas can affect the final cost of work.

Another way to accelerate the speed of work can be by arranging the workstations so that they are more efficient. The idea would be to avoid unnecessary movements of the operators.

Also the operators could have around them some items necessary for welding, such as gas, electrodes, wires, etc. so as to avoid wasting time in obtaining them.

You can have them regularly provide supplies or be given in the morning what they need for the entire day.

Many companies monitor welding jobs through specialized software. This allows them to see how efficiently they are working and saving on energy. In turn, this allows them to know the condition of the equipment of welding.

Any repetitive activity that takes place in the production line should be reviewed to confirm that it is done in the most efficient way possible.

Likewise, it is necessary to take care that the consumables are stored in the correct way, preventing them from getting wet. It should also be checked that there are no gas leaks and take care that other safety standards are met.

How to clean the pieces to be welded?

The best welds come from the pure contact of clean metal with metal. Any foreign material in the welding area can cause imperfections in the weld. Depending on the material, the size and shape of the piece, you can consider some mechanical techniques such as:

The use of the polisher or emery: An angular polisher with an abrasive or wire disc (pleasant) is ideal for preparing steel for MIG or TIG welding. It is not recommended in very thin sheets since it can compromise the resistance of metals.

Orbital polisher: This type of polishers can be useful to clean smooth or flat pieces.

The use of sandpaper or wire brush: It is a manual operation that works very well in cleaning steel parts for MIG and TIG welding or stainless steel, but it can take much longer and does not always eliminate all the oxides or impurities in the metal.

Abrasive blasting: If the metal to be welded is very oxidized and is not suitable for sanding or removing with a polishing machine, another option for preparing the metal is to do it with abrasive blasting.

Traditionally sand has been used, but today there are other materials available.

How to clean the pieces to be welded

Avoid the overwelding

When planning work, determine how much welding certain parts may need. Some companies develop plans to indicate to the operators how much welding they require certain jobs or products and thus avoid that they reinforce more.

Make sure the welds are the right size. If required, for example a 3/16 “fillet and you deposit a 1/4” fillet, it will be oversized by 78% in the amount of welding applied.

By avoiding excessive welding, it reduces waste, reduces application time and reduces the cost of manufacturing.

Also, by better planning the pieces, you can reduce the empty spaces, which end up being covered with solder.

Another way to avoid excess welding is by using the correct process for the application that is occurring. How to choose the appropriate process between TIG, MIG, etc? One of our experts can help you in that. Contact us to advise you in this matter.

The position when welding

It is also necessary to pay attention to the position used for welding. The most recommended is to weld pieces in horizontal position. When that is not the possible position, some operators do not feel so comfortable and the weld bead is deficient.

Welding out of position (for example vertical, or over head) reduces the speed of deposition because gravity acts against us and forces us to work with lower amperages.

The horizontal position allows the operator to use thicker electrodes and execute their work easier and faster.

Keeping the arc in the proper length decreases splashes and concentrates the current in the joint to be welded.

At the moment of welding, the operator does well to check that all the cables are well connected and in good condition. By the way, the appropriate cables should not be too short, so they do not get too hot, nor too long, so they do not waste energy.

The position when welding
The position when welding

What other activities affect the cost of welding?

There are many activities that are necessary and some are more difficult to take into account, but they affect the cost of welding. We can see some before welding and when welding.

Before welding

Preparation of the solder joint: This may include placing a bevel on a plate or simply cleaning the joint to free it from scale, rust, oil or other contaminants.

Assembly: This is to assemble all the parts in an accessory or simply take them to a welding station where the welder can easily take all the necessary components.

Positioning of the piece: In some cases, we can not locate the piece, but when we can, we will move it to weld it more easily.

When welding

Change the filler metal and / or the shielding gas: The wire spools, the bar electrodes and the protection gas bottles when they are finished. We need to account for this time of change.

Breaks and meetings: most companies allow breaks. This can be as little as a 10-minute break in the morning and another 10-minute break in the afternoon. This may also include time for production and safety meetings.

Cleaning: The cleaning that must be done at the end of the day, between shifts, or even between the assembly of each product.

Move the assembly once completed: Once the assembly is completely welded, it must move to another place.

Time for post-welding heat treatment: If necessary, the time for heat treatment after welding should be taken into account.

As can be seen, there are many necessary activities without welding. Some of these can not be eliminated.

Tacking can be eliminated with elaborate accessories. The change of the protection gas bottle can be eliminated by the use of a bulk gas supply system. However, in general all these activities will always be present.

5) Make a Preventive Maintenance (PM) plan

On the other hand, even the best welding equipment will fail if maintenance is not done. That is why preventive maintenance (PM) should be a recurring task in welding workshops.

Without preventive maintenance, equipment will fail at any time, which may mean stopping the entire operation, in some cases.

Many times, after a failure, you have to invest time and staff to find out what the failure might be, and then buy the necessary spare parts to solve it.

Although it can not be avoided that from time to time there are unforeseen events, these can be reduced with a good program of preventive maintenance, which would reduce costs in welding.

Apply management methodologies

Some companies apply the 5S methodology, created by Toyota to increase the productivity of its workers.

With this method work environments are better configured for employees to perform their tasks faster and with fewer risks.

Some of the practices of this methodology is to have closer the equipment and materials that are used more frequently.

The 5S methodology also advocates cleaner and better-groomed workplaces, which helps improve worker motivation and prevents accidents.

Other companies use the Kaizen management method to continuously improve their processes and how they are executed.

Whatever method the company decides to apply, analyzing how it is being worked and the results obtained can help to make decisions that help reduce welding costs.

Codinter have over 40 years supplying the best products for industries. We are expanding in products and markets. We not only are mean to sell products, but also offer services you need to improve your workshop efficiency. Our team is specialized in industrial finishing solutions. Save time and money with us.

In a few words

Reducing costs in welding is a must for any company that performs production processes in metal or whose main objective is the treatment of metals.

You are most welcome to ask whatever you need to know to reduce costs in welding. Our experts not only can help you to define the equipment you would need, but also techniques for the operation execution.

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As a summary, we have done this infographic where you can easily see what is explained in this article.

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Reducing welding costs: 5 effective methods for companies and contractors
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