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Checklist for Cost Reduction

1. Reduce the quantity of weld metal a) Reduce the number of welds b) Dimension weld cross-sections more accurately c) Dimensions weld lengths more accurately d) Weld interrupted welds (check permissibility) e) Restrict tolerances of fillet weld dimensions f) Use deeper penetration g) Assemble to more correct size h) Weld butt welds from both sides (double-vee weld instead of vee weld) j) Reduce weld preparation angle (depending on procedure) k) Change groove shape (U-groove butt weld or square-edge butt weld instead of vee weld) l) Produce more accurate flame cuts, reduce flame cutting distortion m) Reduce sheet metal thicknesses by higher weld quality (weld strength factor) Reduce welding times a) All measures listed in point 1 b) Work with higher deposition efficiency (more current, thicker electrode, high-performance electrode, other shielding gas c) Use other welding procedure with higher output d) Weld in more favourable positions (if necessary use jigs or positioning devices) e) Use weld pool backing (provide for structurally or use as production aid) f) Mechanise g) Improve dissipation of welding heat (e.g. in fully automated thin-sheet welding) h) Train and motivate welders Reduce downtimes and refit times a) Organise production more efficiently (shorten absences and waiting times) b) Organise welders workplace more efficiently c) Inform the welder more effectively d) Ensure good access to the weld e) Get rid of noxious or performance-impeding environmental influences f) Use jigs and fixtures g) Mechanise h) Prevent or reduce distortion (pre-bend, pre-tension, draw up welding sequence schedule, use procedures with less distortion, weld both sides simultaneously) i) Reduce process-dependent interruptions and weld dressing (make slag removal easier, reduce spatter formation, reduce adhesion of spatter, set up central gas supply) k) Reduce malfunction times (purchase quality, operate preventive maintenance, maintain and care for unit regularly, take notice of operating instructions, train and motivate welders) Do not waste energy and consumables a) Save energy (reduce cable losses, switch off unit during breaks, used energy-saving procedures and units) b) Be economical with consumables (do not leave electrode stumps too long, prevent gas losses, watch consumption of spare and wear parts) Monitor quality a) Avoid excessive requirements b) Prevent defects and quality deficiencies

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Bhler Schweitechnik Austria GmbH. - Economy-Checklist for Cost Reduction.doc

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