Towards increased productivity

Towards increased productivity

Why increasing productivity is necessary
Why achieving increased productivity is difficult Factors to consider with every-day welding Increasing productivity ideas

Why increase productivity ??

Todays Reality for Manufacturing Firms
Fierce global competition
Shrinking product cycles Changing criteria for business stability Changing product distribution channels More demanding customers

Why increase productivity ??

Seven truths about change
The pace of change is accelerating We must accommodate change around us In the short term, change can create confusion, inefficiency and loss of morale Most people resist change Change is the only way to improve, progress and learn Change is inescapable We need to understand what is changing and why

Where does your welding dollar go?

Labour & Overheads 70%

$
Typical cost break-down for manual welding
(Varies by Country)

Electrode 17%

Equipment 8%

Power 5%

Where does your welding dollar go?

Electrode 70% Labour and Overhead 17%

$
Typical cost break-down for manual welding
(Varies by Country)

Equipment 8%

Power 5%

Where does your welding dollar go?

Movement of parts into / out of cell 10% Tacking 5% Fixturing and Positioner 15%

Breaks 10% Cleaning 5%

Welding 30%

Grinding 10% Changing Reels / Cylinders 5% Layout 15%

An example of total cycle time

Towards increased productivity

Typical pre & post operations

Heat treating Cutting / Beveling Layout / Assembly

Machining Bending / Forming Drilling / Punching

Tacking / Fixtureing
Painting

Cleaning / Grinding
Trash

Towards increased productivity

Hidden costs

Equipment breakdowns Maintenance costs Service problems Weld repairs Weld finishing

Excessive electrode wastage

Excessive gas wastage

Towards increased productivity

Hidden costs

Electrode baking handling and storage Gas handling and storage Consumables shelf life Inventory requirements Environmental restrictions System redundancy Penalties for late delivery

Ways to increase productivity

Material 30% Welding
10% Cost Reduction Labour & Overheads 70%
10% Price Cut

7%

3%

Bottom Line Pass Through

Welding Cell or Work Station

Ways to increase productivity

Ways to increase productivity

Basic cost of welding formula

Consumable + Labour + Overhead

Consumable =
Cost / kg Efficiency

Labour + OH = (Labour + Overhead rate) x Hours to weld

Hours to weld =
Weight of weld metal required (kg) Deposition rate x Operating factor

Ways to increase productivity

Operating factor
Operating Factor =
Arc-on hours Total work hours

Robotics Automatic Semi automatic Stick electrode

80%
50% 30% 20% Maximum

Ways to increase productivity

Deposition efficiency
Percentage of consumable that becomes weld metal

Submerged Arc GMAW - Short Arc GMAW - Spray Arc FCAW-GS FCAW-GS Metal core FCAW-SS Stick Electrode

100% 95% 90% 85% 98% 82% 60%

10 kg weld metal requires: 10.0 kg 10.5 kg 11.0 kg 11.7 kg 10.2 kg 12.2 kg 16.7 kg

Ways to increase productivity

Deposition rate
Weight of weld metal deposited per hour (kg / hr)

At 200 Amps:

At 300 Amps:

4.0 mm 6013 4.0 mm 7024 1.2 mm ER70S-6

1.7 kg / hr 2.8 kg / hr 3.0 kg / hr

1.2 mm ER70S-6 1.2 mm E71T-1 2.0 mm E70T-4

5.0 kg / hr 5.7 kg / hr 6.9 kg / hr

Ways to increase productivity

Arc time (based on operating factor)
Arc time* =
Weight of weld metal Deposition rate

Operating Factor
At 300 Amps:

At 200 Amps:

4.0 mm 6013 4.0 mm 7024 1.2 mm ER70S-6

50 hours 30 hours 19 hours

1.2 mm ER70S-6 1.2 mm E71T-1 2.0 mm E70T-4

11 hours 10 hours 8 hours

*To deposit 17 kg weld metal (100 m x 6 mm (flat) fillet)

Ways to increase productivity

Reduce over welding

6 mm fillet Vs. 8 mm fillet Weight of weld metal for 100 m flat fillet =

6 mm = 17 kg 8 mm = 30 kg

Ways to increase productivity

Reduce preparation

Ways to increase productivity

Enforce procedure control

Optimum procedure: 1.2 mm ER70S-6 300 amps Actual procedure: 1.2 mm ER70S-6

5 kg / hour

280 amps 4.5 kg / hour

Difference: 10% decrease in deposition rate 10% increase in time, labour and overhead

Ways to increase productivity

Consider joint design

Double bevel = 3 kg / metre Single bevel = 6 kg / metre Reduced welding labour Balanced shrinkage stresses Ensure accessibility from both sides

Ways to increase productivity

Keep up to date with new technology
Waveform control technology Dual process wire feeders / power sources User designable waveforms

Ways to increase productivity

Optimize processes

3 times faster than GTAW

Easier operation than GTAW Low heat input

Ways to increase productivity

Surface Tension Transfer

Suitable for on-shore / off-shore pipelines

STT for root pass FCAW-SS for fill and cap

Root pass requires minimal grinding or patching FCAW-SS can be applied immediately

Ways to increase productivity

Surface Tension Transfer
Can be used for process piping to ASME

Ways to increase productivity

Documented Cost Reduction

Ask your Lincoln Country Manager Have a survey conducted on your premises

Discuss and review opportunities

Work together and achieve documented goals

Questions ?