1. Productivity

7/28/2019 1. Productivity

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Towards increased productivity


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Why increasing productivity is necessary

Why achieving increased productivity is difficult

Factors to consider with every-day welding

Increasing productivity ideas


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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 ??


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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 learnChange is inescapable

We need to understand what is changing and

why

Why increase productivity ??Seven truths about change


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

$Labour & Overheads

70%

Power

5%

Equipment

8%

Electrode

17%

Where does your welding dollar go?


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

$Electrode

70%

Power

5%

Equipment

8%

Labour and Overhead

17%



7/27An example of total cycle time

Welding

30%


Changing Reels / Cylinders

5%

Grinding10%

Cleaning

5%

Breaks

10%

Fixturing and Positioner15%

Tacking

5%Movement of parts into / out of cell

10%

Layout

15%


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Heat treating

Cutting / Beveling

Layout / Assembly

Tacking / Fixtureing

Painting

Machining

Bending / Forming

Drilling / Punching

Cleaning / Grinding

Trash

Typical pre & post operations



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Equipment breakdowns

Maintenance costs

Service problems

Weld repairs

Weld finishing

Excessive electrode wastage

Excessive gas wastage

Towards increased productivityHidden costs


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Electrode baking handling and storage

Gas handling and storage

Consumables shelf life

Inventory requirements

Environmental restrictions

System redundancy

Penalties for late delivery

Towards increased productivityHidden costs


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Labour & Overheads

70%

Welding Cell or Work Station

7%

10% Cost

Reduction

10%Price Cut

Welding

Material30%

3%

Bottom Line Pass Through

Ways to increase productivity


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Ways to increase productivityBasic cost of welding formula

Labour+Consumable + Overhead

Consumable = EfficiencyCost / kg

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

Hours to weld =Deposition rate x Operating factor

Weight of weld metal required (kg)


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Ways to increase productivityOperating factor

Operating Factor =Total work hours

Arc-on hours

Robotics 80%

Automatic 50%

Semi automatic 30%

Stick electrode 20% Maximum


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Ways to increase productivityDeposition efficiency

Percentage of consumable that becomes weld metal

Submerged Arc 100% 10.0 kg

GMAW - Short Arc 95% 10.5 kg

GMAW - Spray Arc 90% 11.0 kg

FCAW-GS 85% 11.7 kg

FCAW-GS Metal core 98% 10.2 kg

FCAW-SS 82% 12.2 kg

Stick Electrode 60% 16.7 kg

10 kg weld metal requires:


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Ways to increase productivityDeposition rate

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

4.0 mm 6013 1.7 kg / hr

4.0 mm 7024 2.8 kg / hr

1.2 mm ER70S-6 3.0 kg / hr

At 200 Amps:

1.2 mm ER70S-6 5.0 kg / hr

1.2 mm E71T-1 5.7 kg / hr

2.0 mm E70T-4 6.9 kg / hr

At 300 Amps:


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Ways to increase productivityArc time (based on operating factor)

Arc time* =Deposition rate

Weight of weld metal Operating Factor

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

4.0 mm 6013 50 hours

4.0 mm 7024 30 hours

1.2 mm ER70S-6 19 hours

At 200 Amps:

1.2 mm ER70S-6 11 hours

1.2 mm E71T-1 10 hours

2.0 mm E70T-4 8 hours

At 300 Amps:


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6 mm fillet Vs. 8 mm fillet

Weight of weld metal for 100 m flat fillet =

Ways to increase productivityReduce over welding

6 mm = 17 kg

8 mm = 30 kg


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Ways to increase productivityReduce preparation


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Optimum procedure:

1.2 mm ER70S-6 300 amps 5 kg / hour

Actual procedure:

1.2 mm ER70S-6 280 amps 4.5 kg / hour

Difference:

10% decrease in deposition rate

10% increase in time, labour and overhead

Ways to increase productivityEnforce procedure control


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Double bevel = 3 kg / metre

Single bevel = 6 kg / metre

Reduced welding labour

Balanced shrinkage stresses

Ensure accessibility from both sides

Ways to increase productivityConsider joint design


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Dual process wire feeders / power sources

User designable waveforms

Waveform control technology

Ways to increase productivityKeep up to date with new technology


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Ways to increase productivityOptimize processes

3 times faster than GTAW

Easier operation than GTAW

Low heat input


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Ways to increase productivitySurface 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


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Can be used for process piping to ASME

Surface Tension Transfer


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Ask your Lincoln Country Manager

Have a survey conducted on your premises

Discuss and review opportunities

Work together and achieve documented goals

Ways to increase productivityDocumented Cost Reduction


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Questions ?

1. Productivity

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