Subscribe

(https://weldingproductivity.com/)

 (http://twitter.com/weldingmagazine)  (http://www.pinterest.com/weldingmagazine)
 (https://www.linkedin.com/company/welding-productivity-magazine)
(https://www.facebook.com/Welding-Productivity-1168602596586046/)
(http://www.fsmdirect.com/)

THE MAGAZINE NEWS MEDIA KIT ABOUT CONTACT Search Site 

(HTTPS://WELDINGPRODUCTIVITY.COM/NEWS/)
(HTTPS://WELDINGPRODUCTIVITY.COM/MEDIA-
(HTTPS://WELDINGPRODUCTIVITY.COM/ABOUT/) (http://shopfloorlasers.com/)
KIT/)

WELDING PRODUCTIVITY

Tracking welding productivity MAGAZINE

Experience the full version of this

article in our magazine.
MEASURING AND IMPROVING WELDING PRODUCTIVITY
COMES DOWN TO KEEPING TRACK OF THE DETAILS.
VIEW ARTICLE IN READER
By: Karsten Madsen, welding consultant, OptiWeld Tweet
(HTTP://WWW.NXTBOOK.COM/NXTBOOKS/W

Manufacturing managers and supervisors often look blindly at welding operations without really
understanding how to measure and assess productivity. A common phrase heard in the shop
could be something along the lines of: “I see arc radiation flashing on and off, therefore, parts are ARTICLES BY TYPE
getting welded.”
Welding
The danger with that is that competitors both locally and globally are introducing lean (https://weldingproductivity.com/type/welding/)
manufacturing methods to all aspects of their operations, including welding. They’re streamlining (44)
their processes and they’re doing so by keeping a thumb on every aspect of production – and Robotics
every weld that’s being made. (https://weldingproductivity.com/type/robotics/)
(30)
Therefore, to remain competitive, companies must continually seek out ways to improve their Fume Extraction
welding quality and productivity. Too many companies, however, aren’t looking at their welding (https://weldingproductivity.com/type/fume-
processes at a granular level, which means that they can’t maximize profit potential or, worse yet, extraction/) (24)
they lose orders due to inefficient welding methods. Cutting & Prep
(https://weldingproductivity.com/type/cutting-
This approach doesn’t just affect individual companies, though. To have a healthy economy, a prep/) (22)
good slice of the employment pie needs to be jobs where workers manufacture widgets. If we want Systems & Equipment
to continue welding machinery, pressure vessels and other parts, we have to better analyze our (https://weldingproductivity.com/type/systems-
operations under a manufacturing magnifying glass and then use world-class lean manufacturing equipment/) (21)
methods. Sawing
(https://weldingproductivity.com/type/sawing/)
If we ignore this challenge and do not introduce new and productive welding methods, more and (19)
more young people will be bumped into lower wage service sector jobs, or worse yet, the Consumables
unemployment line. Incomes and tax revenue will be reduced and you, I and our neighbors will (https://weldingproductivity.com/type/consumables/
pay the price for not investing in welding productivity. (18)
Safety

Factors for productivity (https://weldingproductivity.com/type/safety/)

(15)
With that ominous introduction to welding productivity aside, let’s take a look at how to measure Plasma
and improve it. One way to go about it is by looking at a deposition rate productivity measurement (https://weldingproductivity.com/type/plasma-
method, which is preferred for heavy welding applications, including multi-pass welds (think pound cutting-prep/) (15)
weld per hour). But, for sheet metal, single pass or autogenous applications, travel speed is a Training
better measuring stick. (https://weldingproductivity.com/type/training/)
(15)
This is also the first category for making welding productivity improvements – while welding, weld Abrasives and Deburring
faster. A primary variable to focus on is wire feed speed for the many variations of continuous wire (https://weldingproductivity.com/type/abrasives-
processes. Wire diameter is another factor, and it may not be as simple as the larger wire and-deburring/) (15)
translating into faster welding. Some studies suggest that faster wire feed speeds of a smaller Laser
diameter wire may translate into higher deposition rates. (https://weldingproductivity.com/type/laser-
welding/) (14)
The second category to consider in welding productivity is the operating factor, which is also Filler Metals
referred to as arc-on time. In doing time studies and using arc timers, surprising data emerged (https://weldingproductivity.com/type/filler-
surrounding welders using manual or semiautomatic modes of welding. The data indicated that metals/) (11)
some welders were only welding for 20 to 35 percent of the time. This then becomes the single Automotive
most important value in trying to improve welding productivity. Therefore, efforts should be made (https://weldingproductivity.com/type/automotive/)
(10)
to determine realistic operating factors for various applications. While non-welding tasks Arc
performed by welders are certainly needed, including cleaning and heating, productivity gains in (https://weldingproductivity.com/type/arc-
this category would focus on ways to minimize the 65 to 80 percent of non-welding tasks welding/) (10)
performed by welders that do not add value to the product. PPE
(https://weldingproductivity.com/type/ppe/)
The third category influencing welding productivity is in regard to how much weld metal is (8)
deposited and what endeavors are being taken to increase productivity by decreasing this amount. Wire
For deposition rate-based applications, the total weld weight needs to be calculated for each (https://weldingproductivity.com/type/wire/)
welding method to be used, while total weld lengths only need to be determined when using travel (7)
speed-based welding productivity measurement. Oxyacetylene
(https://weldingproductivity.com/type/oxyacetylene/)
Reductions in weld metal deposited can be made with alternate weld joint designs or in (6)
considering fillet welds based on throat dimension instead of the more usual leg length because TIG
the throat is a better measurement of effective weld strength. Interesting to note is that some (https://weldingproductivity.com/type/tig/)
structural steel welding codes allow smaller fillet weld sizes when the submerged arc welding (6)
process is used. ISO welding symbols take that a step further by permitting engineers to specify GMAW
fillet size by leg length or by throat dimension. (https://weldingproductivity.com/type/gmaw/)
(5)
Another improvement in doing less welding is in minimizing the amount of overwelding and rework Aluminum
welding. Some are surprised to hear that a specified 1/4-in. weld made oversize by 1/16 will take (https://weldingproductivity.com/type/aluminum/)
56 percent more time. Simple geometric calculations prove this out. (4)
Gases
(https://weldingproductivity.com/type/gases/)
(4)
Trade Shows
(https://weldingproductivity.com/type/trade-
shows/) (4)
Aerospace
(https://weldingproductivity.com/type/aerospace/)
(3)
Military
(https://weldingproductivity.com/type/military/)
When business owners better understand how to calculate the cost of their welding operations, the pursuit to
(3)
increase productivity becomes much easier.
Steel
So with the simple formula visualized, it’s easy to see: Better welding productivity includes faster (https://weldingproductivity.com/type/steel/)
welding, more arc-on time and less welding (less metal deposited). To further illustrate what may (3)
be possible, let’s review some situations straight from the weld shop floor. Tube and Pipe
(https://weldingproductivity.com/type/tube-
Shop floor insight and-pipe/) (3)
Friction Stir Welding
In one case, a shop did not use formal welding procedures – an inspector explained that it was up (https://weldingproductivity.com/type/friction-
to the welders to set their machines to make good welds. A series of similar-looking “good” welds stir-welding/) (3)
were then made the same size. When asked if any were defective, the inspector replied that they Resistance Welding
all looked fine. From a productivity standpoint, however, there was a huge difference in the welds (https://weldingproductivity.com/type/resistance-
made with the minimum wire feed speed of 300 ipm to a maximum of 600 ipm. The result was a welding/) (3)
100 percent increase in productivity. Shop Floor Productivity
(https://weldingproductivity.com/type/shop-
To give an example of an operating factor improvement, let’s look at a supervisor who wanted the floor-productivity/) (2)
company’s welders to get more life out of their gun contact tips. His instructions were, “If you use a Electric Resistance Welding
tip cleaner, you can get rid of the spatter and burnback.” But what he wasn’t factoring in was the (https://weldingproductivity.com/type/electric-
cost of cleaning contact tips. Using six minutes of non-welding time for this work and using typical resistance-welding/) (2)
shop labor and overhead rates, welders would have spent $30 trying to get more life out of a $0.80 Heavy Equipment
worn-out consumable. (https://weldingproductivity.com/type/heavy-
equipment/) (2)
In another shop, fillet weld sizes were measured in production and inventory and then compared Agriculture
to engineering drawing size requirements. What might have seemed insignificant – with some (https://weldingproductivity.com/type/agriculture/)
welds having leg lengths 1/16 in. oversize – resulted in a surprising amount of overwelding once (2)
geometric calculations were made. Overall, the 15 percent oversize welds would have translated Quality Control
into $600,000 of wasted welding each year based on the annual welding cost of $4 million at this (https://weldingproductivity.com/type/quality-
specific shop. control/) (2)
Power Tools
To see the ROI of the cost to measure, implement and monitor productive welding methods, let’s (https://weldingproductivity.com/type/power-
take a look at a hypothetical, medium-sized shop employing 50 welders. With a combined labor, tools/) (1)
benefits and overhead rate of $60 per hour with each welder working 40 hours per week, the Post Processing
annual welding cost calculation can quickly be determined. (https://weldingproductivity.com/type/post-
processing/) (1)
 Now, let’s Underwater Welding
assume (https://weldingproductivity.com/type/underwater-
that a 10 welding/) (1)
percent General Fabrication
savings (https://weldingproductivity.com/type/general-
could be fabrication/) (1)
achieved in software
each of the (https://weldingproductivity.com/type/software/)
three (1)
categories
previously
explained. ISSUES
That 30
percent September 2019
reduction (https://weldingproductivity.com/issue/september-
would 2019/) (6)
result in a August 2019
savings of (https://weldingproductivity.com/issue/august-
more than 2019/) (5)
$1.8 July 2019
The Canadian Welding Bureau website features an online calculator that automates and million, (https://weldingproductivity.com/issue/july-
simplifies much of the complex calculations required to measure welding productivity. 2019/) (6)
which is a
strong June 2019
argument for investing in welding productivity. This is done by hiring the staff, doing analyses to (https://weldingproductivity.com/issue/june-
optimize welding operations, and then purchasing equipment and materials if necessary to put 2019/) (7)
new welding process control methods to work. May 2019
(https://weldingproductivity.com/issue/may-
Hiring competent welders can be a challenge, which is sometimes compounded with comments 2019/) (5)
like, “I need to weld the way I feel is right.” But to control welding quality and productivity, explicit April 2019
procedures should be developed, documented and then actually used by welders instead of just (https://weldingproductivity.com/issue/april-
having them come out of filing cabinets during quality audits. Shop floor monitoring of procedure 2019/) (7)
compliance and supporting personnel who need training can help minimize an out-of-control March 2019
welding free-for-all. Instead of having 50 welders doing their own thing, the goal is to have (https://weldingproductivity.com/issue/march-
everyone use the best welding method for the job at hand. 2019/) (6)
February 2019
Some companies have no problems handing out recruiting ads for welders when they have (https://weldingproductivity.com/issue/february-
production hours available. On the other hand, some companies have been reluctant to hire 2019/) (5)
welding experts to manage their welding and may pay the price with inefficient operations. January 2019
Recognizing that small- to medium-sized shops may have difficulty justifying the expense of a (https://weldingproductivity.com/issue/january-
welding technologist, there may be ways to develop that expertise with existing personnel or by 2019/) (5)
using outside organizations. December 2018
(https://weldingproductivity.com/issue/december-
Suppliers of welding products, like Praxair (http://www.praxair.ca/en/industries/welding-and-metal- 2018/) (6)
fabrication/starsolver-productivity-enhancement-program), often have skilled technical staff and, in November 2018
some cases, also offer welding productivity audits and services. With confidence in the (https://weldingproductivity.com/issue/november-
representatives and unbiased reports from these services, they can provide assistance in 2018/) (5)
understanding the productivity of current methods and make recommendations for improvements. October 2018
(https://weldingproductivity.com/issue/october-
Another option when developing expertise in managers and supervisors is with services like those 2018/) (7)
offered by the Canadian Welding Bureau September 2018
(http://https://www.cwbgroup.org/education/courses/welding-productivity). The CWB, for example, (https://weldingproductivity.com/issue/september-
has a welding productivity course and online tools that develop skills in measuring welding 2018/) (6)
productivity. The site includes an online calculator that automates and simplifies much of the August 2018
complex calculations required. Once accurate data exists for welding methods, informed decisions (https://weldingproductivity.com/issue/august-
can be made on procedure selection and in taking an analytical approach to improving 2018/) (7)
productivity. July 2018
(https://weldingproductivity.com/issue/july-
No matter the company size, welding continues to be a labor-intensive process, but as this article 2018/) (6)
has outlined, improvements in productivity are possible. By having realistic data for welding June 2018
productivity and cost, intelligent manufacturing decisions can be made, thereby increasing profits (https://weldingproductivity.com/issue/june-
to keep well-paying jobs in our backyard. 2018/) (7)
May 2018
To further drive home the idea of improving welding productivity, there is a final valuable lesson to (https://weldingproductivity.com/issue/may-
learn from a shop that did not weld to code requirements. The company didn’t use welding 2018/) (6)
procedures to guide its 50 welders, and even if it did, only some of their GMAW/MCAW machines April 2018
had digital controls making setup a challenge. (https://weldingproductivity.com/issue/april-
2018/) (7)
To assess the competence of the welders, they were asked to do a welding test and record the March 2018
parameters they used, which required a manual technique on the analog control machines. Once (https://weldingproductivity.com/issue/march-
all of the welders had completed the test, recommendations followed. 2018/) (6)
February 2018
The final report, produced by OptiWeld, indicated a 53 percent variance in wire feed speed (https://weldingproductivity.com/issue/february-
settings used by the welders, which is directly proportional to productivity and quality. Once that 2018/) (6)
variance was reduced, productivity improved, proving that welding process control requires January 2018
developing optimum procedures and then providing the training and resources so that they can be (https://weldingproductivity.com/issue/january-
implemented across the board. 2018/) (5)
December 2017
(https://weldingproductivity.com/issue/december-
2017/) (6)
November 2017
(https://weldingproductivity.com/issue/november-
2017/) (7)
October 2017
(https://weldingproductivity.com/issue/october-
2017/) (7)
September 2017
(https://weldingproductivity.com/issue/september-
2017/) (6)
August 2017
Previous Article Next Article (https://weldingproductivity.com/issue/august-
2017/) (6)
Heavy customization Beyond cutting July 2017
(https://weldingproductivity.com/article/heavy- (https://weldingproductivity.com/article/beyond- (https://weldingproductivity.com/issue/july-
customization/) cutting/) 2017-issue/) (7)
June 2017
(https://weldingproductivity.com/issue/june-
2017/) (6)
May 2017
(https://weldingproductivity.com/issue/may-
2017/) (7)
April 2017
(https://weldingproductivity.com/issue/april-
2017/) (6)
March 2017
(https://weldingproductivity.com/issue/march-
2017/) (6)
February 2017
(https://weldingproductivity.com/issue/february-
2017/) (6)
January 2017
(https://weldingproductivity.com/issue/january-
2017/) (6)
December 2016
(https://weldingproductivity.com/issue/december-
2016/) (6)
November 2016
(https://weldingproductivity.com/issue/november-
2016/) (7)
October 2016
(https://weldingproductivity.com/issue/october-
2016/) (8)
September 2016
(https://weldingproductivity.com/issue/september-
2016/) (7)
August 2016
(https://weldingproductivity.com/issue/august-
2016/) (5)
July 2016
(https://weldingproductivity.com/issue/july-
2016/) (5)
June 2016
(https://weldingproductivity.com/issue/june-
2016/) (7)
 May 2016
(https://weldingproductivity.com/issue/may-
2016/) (5)
April 2016
(https://weldingproductivity.com/issue/april-
2016/) (6)
March 2016
(https://weldingproductivity.com/issue/march-
2016/) (7)
February 2016
(https://weldingproductivity.com/issue/february-
2016/) (5)
January 2016
(https://weldingproductivity.com/issue/january-
2016/) (5)
November / December 2015
(https://weldingproductivity.com/issue/november-
december-2015/) (7)
September / October 2015
(https://weldingproductivity.com/issue/september-
october-2015/) (7)
July / August 2015
(https://weldingproductivity.com/issue/july-
august-2015/) (8)
May / June 2015
(https://weldingproductivity.com/issue/may-
june-2015/) (8)
March / April 2015
(https://weldingproductivity.com/issue/march-
april-2015/) (7)
January / February 2015
(https://weldingproductivity.com/issue/january-
february-2015/) (9)

SUBSCRIBE NOW FOR FREE

Email

Email address

First Name

First name

Last Name

Last name

SUBSCRIBE

(./)

NAVIGATE CONNECT CONTACT PARTNERS &

PUBLICATIONS
The Magazine  Twitter Welding Productivity
(https://weldingproductivity.com/issues/)(http://twitter.com/weldingmagazine) Techgen Media Group®
News  Pinterest
Magazine® (http://techgenmedia.com)
PO Box 516
(https://weldingproductivity.com/news/)(http://www.pinterest.com/weldingmagazine) FAB Shop Magazine Direct®
Media Kit  LinkedIn Plainsboro, NJ 08536 (http://www.fsmdirect.com)
(https://weldingproductivity.com/media-(https://www.linkedin.com/company/welding- Shop Floor Lasers Magazine®
kit/) productivity-magazine) (http://www.shopfloorlasers.com)
About Sawing Productivity®
(https://weldingproductivity.com/about/) (http://sawingproductivity.com)
Contact Modern Abrasives & Deburring
(https://weldingproductivity.com/contact/) Magazine®
(http://modernabrasivesdeburring.com/)
Praxair Corp.
(http://www.praxair.com)

©2019 Welding Productivity® Magazine Inc. Site by East Slope Studio (http://eastslopestudio.com)