Total Welding Management

 

 

 

 

 

 

 

 

 

 

 

 


                       Reducing the non-productive hours in each of the five welding Do’s

 

REDUCE WELD METAL VOLUME:

ü  One of the most common problems is the mindset that the “bigger the weld volume, better the weld “which is fundamentally wrong.

ü  Over welding adds to the labour cost and causes shrinkage and distortion.

ü  Correct specification of the child parts should be ensured to ensure the proper fit-up and weld specification.

ü  Reduced weld size and weld joint openings will result in less weld metal volume and decreased shrinkage and distortion.

ü  Awareness to be provided to the welders to prevent welding them in higher sizes than required.

REDUCE ARC TIME PER WELDMENT:

ü  Arc time can be reduced by selecting the proper process, filler metals, and manpower.

ü  Weld joint position, clean parts, fit-up and weld joint accessibility are also contributing factors.

ü  This goal is complimentary to the first goal. However, if the process and joint design are optimized both goals can be achieved.

REDUCE REJECTS, REWORKS AND SCRAPS :

The Rejected or reworked components always compromise the quality and loss their integrity. Hence, controls are required to assure the following areas.

1. Qualification of the welder

2. Workmanship standards

3. Proper welding procedure

4. Qualified work method

5. Works to permit specification.

When this goal is accomplished it eliminates the cost, of unproductive labour associated with rejects, rework and scraps.

 REDUCE WORK EFFORT:

In any physical work, efficient job movement reduces fatigue.

1.      Welding fixtures

2.      Proper workstation layout

3.      Equipping with proper tools and layout

4.      Training the welders

5.      Weld sequencing

      Work effort refers to the degree of difficulty, frustration, fatigue, and hazards. This goal tends to reduce all the factors which affects the difficulty of work. Eg, welder ergonomics.

REDUCE MOTION AND DELAY TIME:

The Production worker is more efficient when his motions are optimized, placing parts close to the welder can reduce motion and make the welder more productive.

Through a good system of work centre and planning and control, the amount of time spent making value-added welds will be maximum.

 

 

 

FOUR CRITICAL DEPARTMENTS AND THEIR FUNCTIONS

                                                                    

DESIGN ENGINEERING :

è Base material selection

è Weld size determination

è Weld joint selection

è Manufacturing review

è Weld material specification

MANUFACTURING ENGINEERING :

è Workmanship standard

è Welding process

è Equipment tooling and  selection

è Work centre planning

QUALITY ASSURANCE :

è Policy and accountability

è Quality standards

è Inspection measure and reports

è Corrective action

Manufacturing operations

è Personal training

è Material input

è Equipment performance

è Method application.

 

Reference: TOTAL WELDING MANAGEMENT,   Jack R. Barckhoff, P.E.

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