In the auto – truck industry, you will find maintenance electricians, millwrights and plumbers each shift making unqualified weld changes to robot welds. It seems someone forget to tell the management in these plants that most of these individuals know nothing about robot MIG weld process controls – best practices..
A look at the root cause reasons for global manual and robot MIG and flux cored weld process confusion.
Manual or robot MIG weld costs, who in the front office has a clue?
Lets take a look at the the global influence of SALES ADVICE on manual – robot weld quality, productivity & costs.
Why lasers dont belong in the auto – truck industry, and management and those robot & laser aluminum welds.
In large industries you will find that billions of dollars are lost each years due to lack of weld process controls and best weld practice expertise.
Why the auto – truck company management waste millions of dollars annually on the unnecessary purchase of laser weld – cutting & tracking systems.
There is no reason for a global skilled MIG – Flux Cored welder shortage.
The corporate managers / engineers at Chrysler did not have loose millions of dollars each year on a simple robot welded part.
Ford, reasons for it’s robot steel frames and aluminum weld issues.
The auto management and engineering influence on the billions of dollars lost every year in vehicle recalls & law suites.
Why I would not trust any Chinese company to create products or construction projects that consistently require optimum weld quality.
Few of the global robots daily achieve their production – quality potential.
Why Dow Chemical engineers and management are stuck in a 1960s weld time warp.
Magna technicians lots of attitude, but still lack Robot MIG Weld Process Control expertise.
What do ship yards and auto plants have in common?
Why the common global QA weld inspection practices often fail.
When US robot welds fail the solution is ship the parts to Mexico.
Nothing is more ridiculous than having the pathetic FEMA organization involved with USA weld specs.
Would Einstein’s have this theory on MIG welding?
Pathetic Self Shielded flux cored wires, and a prime reason the North Ridge earth quake welds failed.
With Motoman there were always numerous robot / weld weld issues.
Another reason many robot plant – engineering managers and supervisors have raised the white flag.
For approx. four decades, most of the three part MIG gas mixes sold have simply been a CON job.
I told this Asheville Volvo plant mg. that he was wrong in wanting to hire skilled welders to run his robots.
Lawyers may want to read this section to find out how the inconsistent, poor MIG – Resistance weld quality affects vehicle crashes.
At this Volvo truck plant, automated weld quality and productivity could not be achieved with this Volvo manager and engineer?
The fear of weld process change is natural in plants in which the management and engineers responsible are not in control of the weld equipment and processes they own.
In contrast to most othe large fab shops, the ratio of engineers to shop floor workers is very high in the auto – truck industry. Yet in this vehicle industry weld best practices and the weld process controls necessary for automated weld quality – productivity optimization are typically rare or none exist ant.
Many plant or manufacturing managers will often not report the real robot weld quality and productivity costs to their corporate peers.
There are hazards and restrictions when building vehicles that are designed by engineers who would not know a good MIG or resistance weld if it was four inches from their nose.
Why Americans should give consideration the the welds before they drive across that next steel bridge.
This world’s largest auto – truck wheel manufacturer produced poor and inconsistent quality robot welds and their apathetic, inexperienced management helped drive this company out of business.
Is it logical to want those that are paid to daily make manufacturing process decisions to understand the scope, accountability and responsibility of their profession?
Why did the GM senior management waste nearly a million dollars for equipment to weld the Corvette?
IT’S A SAD FACT REFLECTION ON THE GLOBAL MANAGEMENT / ENGINEERING MIG WELD PROCESS CONTROL EXPERTISE, THAT THIS YEAR AS IT’S BEEN FOR DECADES, A MAJORITY OF THOSE COMPANIES THAT USE MIG WELD ROBOTS AND DECIDE TO PURCHASE ADDITIONAL ROBOTS, WILL NOT BE AWARE THAT IN MANY INSTANCES, THE ROBOTS THEY ALREADY OWN WILL HAVE NEVER REACHED THEIR WELD PRODUCTION OR QUALITY POTENTIAL. WELCOME TO SECTION 4.
Their were many weld issues in the plant and the management are again looking to blame the wrong people.
The most costly pulsed MIG Lincoln power source versus the least costly CV Lincoln MIG power source.
The Miller Maxtron and Invision helped put this global wheel mfg. into Chapter 11.
After introducing their new pulsed MIG equipment, most weld equipment manufacturers continuously made changes to the equipment without notifying their customers about the many electronic changes made and about the nagative impacts the problems have caused on welds..
Japan always made the worst MIG equipment and Japanese auto – truck weld specifications often belong in Disney Land.
Why purchase a costly pulsed MIG power source for gage metals, when in most instances the lower cost CV power source with SC is superior.
Why purchase a costly pulsed MIG power source for welding steels > 1/16, when the lower cost CV equipment with the spray mode will in most instances provide superior weld fusion, less porosity, improved arc stability and higher weld deposition rate potential.