MIG Short Circuit Weld Best Practice and Weld Process Controls for thin parts, gaps and root welds MIG Spray Transfer Weld Process Controls for welds on parts thicker than 3mm Pulsed MIG Weld Process Controls MIG Equipment - Consumables Evaluation MIG Gas Mix. Information without salesmanship Robot MIG Technician Tips Robot MIG Management Tips MIG weld Duplex - Alum - Stain and all Alloys Flux Core Pipe and Plate Weld Process Controls Flux Cored Weld Problems. Pipe Lines, Ship Yards, Tanks, Pressure Vessels and Construction Projects Self Shielded Flux Cored Weld Issues TIG - GTAW Weld Tips TIG - GTAW Weld Tips Oxy - Fuel Cutting Data Bad Weld Sections, General Industry Bad Weld Section, Auto & Truck Industry
All Weld Programs Ed's Process Control Training Resources Who is Ed Craig?
Advanced TIP TIG Welding

At www.tiptigusa.com, you will find a weld process that always produces superior weld quality than TIG, and is 100 to 500% faster.


Welcome to the world's largest web site on MIG , Flux Cored and TIG. Weld Process Controls & Best Weld Practices. To get to the root cause of weld issues requires Weld Process Controls & Best Weld Practice expertise, & lots of weld reality. The site provides the MIG - Flux Cored - TIG weld information necessary to attain the highest possible manual and robot weld quality, always at the lowest possible weld costs.

This web provides the "Personnel Views of Ed Craig". The site was established in 1997. Contact ecraig@weldreality.com

 

 

Weld Reality Home Page 2.
Page one is Here.



WELD MANAGEMENT RARELY VISITS THIS WEB SITE, LETS FACE IT THEY ARE OFTEN TOO BUSY TRYING TO DOWSE THEIR WELD SHOP FIRES.

IF THEY DID VISIT THIS SITE THEY WOULD HAVE LESS CONCERNS FOR MANUAL & ROBOT, MIG & FLUX CORED, WELD QUALITY - PRODUCTIVITY - REWORK - REJECTS - RECALLS AND WELD LIABILITY ISSUES, THAT IS ONCE THEY AND THEIR SUPERVISORS AND TECHNICIANS BECOME FAMILER WITH THE WELD PROCESS CONTROLS & BEST WELD PRACTICES AVAILABLE AT THIS WEB SITE.

 


Please refresh this page
as updates are frequent
:


Please make sure you check all weld REALITY programs.

 

WELD PROCESS CONTROLS - BEST WELD PRACTICE EXPERTISE IS READILY
SEEN WHEN COMPLEX AUTOMATED WELDS ARE REQUIRED.

 

Inconel or stainless weld clad area, 2 to 20.000 sq/feet. Ed's boiler wall clad MIG weld patent.
The welds shown are untouched, & the single MIG gun deposition rate was approx. 16 lb/hr.

In the 1990's, Ed developed the above USA - Europe "Pulsed MIG Overlay Clad Weld Patent". For this patent Ed created a unique pulsed program. One of the few applications that pulsed provides real world weld benefits is low dilution clad welds, especially when utilizing sluggish alloys. Ed's patent was was developed for WSI (Aquilex) Atlanta. This company uses approx. 1 million pounds of stainless / inconel and other alloy wires each year on clad applications. Ed's patent dramatically improved the cladd weld quality that globally is applied to Power Stations and Waste Energy Plants Water Wall Boilers and other components. Ed's patent also dramatically lowered the typical required costly Inconel / Stainless weld consumable costs by approx 25 - 30% per sq/ft. Another benefit for the power industry water wall industry, was the unique clad weld quality and low single pass weld dilution provided weld results that dramatically reduced the clad weld stresses, (increases boiler longevity). Click here for info.

Note: The Single Layer clad welds, would when tested have to indicate less than 7% dilution to acheive a single pass chrome content of > 20%. Ed's average single pass weld dilution was approx. 5%. His spatter free, "single MIG torch clad weld deposition rate achieved an average weld deposition rate of approx. 16 lb/hr.


 



AN INDICATION OF MIG WELD PROCESS CONTROL EXPERTISE IS EVIDENT WHEN ROBOT MIG WELDS WHICH IN REALITY ARE MADE BY DUMB - BLIND MACHINES CONSISTENTLY ATTAIN THE HIGHEST POSSIBLE MIG WELD QUALITY AND PRODUCTIVITY.. IMPOSSIBLE TO ATTAIN WITHOUT WELD PROCESS - CONTROLS AND BEST ROBOT WELD PRACTICE EXPERTISE. ED HAS ESTABLISED A HIGHLY EFFECTIVE 7 STEPS TO ROBOT WELD OPTIMIZATION PROGRAM.



INCREASING MIG DEPOSITION RATES ALLOWS FASTER WELD SPEEDS. INCREASING WELD SPEEDS WITH MIG IS ONE OF THE MOST LOGICAL METHODS TO REDUCE WELD HEAT AND DILUTION. THE MAJORITY OF ALL WELD APPLICATIONS, ESPECIALLY ALLOY WELDS, TYPICALLY BENEFIT FROM ATTAINING THE LOWEST POSSIBLE WELD HEAT. A PROCESS THAT ED BOUGHT TO NORTH AMERICA IS CALLED TIP TIG. THIS PROCESS PROVIDES THE HIGHEST POSSIBLE TIG WELD QUALITY WITH EN POLARITY IT THERFORE PROVIDES THE LOWEST POSSIBLE WELD HEAT.

2008: Automated or Manual welds. The capability of weld management, engineers and supervisor s in any industry is easily measured in their weld process control - best weld practice evolution, and in their accepatance of new weld processes and weld consumables that actually provide real world weld / part benefits..

 

TIP TIG, THE WORLD'S MOST IMPORTANT WELD PROCESS, PITY THAT
FEW MANAGERS OR ENGINEERS HAVE BEEN AWARE OF IT.



It would take 6 to 8 regular TIG welders to produce the weld same production as the above two TIP TIG welders, and with traditional TIG, they could not attain the same weld quality as attained with TIP TIG. In a time when finding highly skilled TIG welders is difficult task for most managers, why would any manager have an interest in the TIP TIG process which dramatically lowere the welder skills and providess much higher weld manual / automated weld productivity and quality?


AERO SPACE, DEFENCE, NUCLEAR, POWER PLANT, OIL, GAS MEDICAL AND FOOD INDUSTRIES WAKE UP,

2016: Note: IT'S A SAD REFLECTION OF THE GENERAL LACK OF WELD ENGINEERING AND MANAGEMENT WELD PROCESS EXPERTISE, THAT IN THOSE HIGH TECH INDUSTRIES THAT PRODUCE CODE QUALITY AND ALLOYS WELDS, THAT AFTER ALMOST TWO DECADES SINCE IT'S INTRODUCTION, FEW WELD DECISION MAKERS ARE AWARE OF THE TIP TIG PROCESS.

THE HIGHLY EVOLVED GTAW (TIG) PROCESS IS CALLED TIP TIP. IN 2008 AS IT HAS BEEN FOR A DECADE, THIS PROCESS WAS BOUGHT TO NORTH AMERICA BY MYSELF AND BUISNESS PARTNER TOM O'MALLEY, I FOUND THIS BRILLIANT AUSTRIAN INVENTION AT MY FREIND'S DARREN MATHERSON LOCATION IN SCOTLAND.

TIP TIG PROVIDES NUMEROUS MANUAL - AUTOMATED WELD QUALITY - WELD COST BENEITS FOR NUMEROUS WELD APPLICATIONS. UNFORTUNAely IN AN INDUSTRY THAT IS GUIDED BY THE LOCAL WELD SALES ADVICE, IT MAY TAKE ANOTHER TWO DECADES BEFORE THE KEY WELD DECISION MAKERS IN THE HIGH TECH INDUSTRIES WAKE UP TO WELD REALITY OF TIIP TIG.

Note: More info on TIP TIG in the TIP TIG program at this site.

 





1956 - 2016... A RARE ACHIEVEMENT
IN ANY GLOBAL WELDING SHOP.

MIG - FLUX CORED WELDER EXPERIENCE, HAS LITTLE TO DO WITH WELD PROCESS CONTROLS - BEST WELD PRACTICE EXPERTISE.

2016: ONE THING ALL INDUSTRIES HAVE IN COMMON, MOST WELD MANAGERS AND SUPERVISORS HAVE FOR MORE THAN FOUR DECADES NOT FIGURED OUT THAT MIG - FLUX CORED "WELDER EXPERIENCE & WELDER SKILLS" HAS NOTHING TO DO WITH WELD PROCESS CONTROLS - BEST WELD PRACTICE KNOWLEGE:

WHILE MANY MANAGERS / ENGINEERS USE THE WORDS "BEST WELD PRACTICES" UNFORTUNATELY FEW WILL BE AWARE OF THE WELD PROCESS CONTROL EDUCATION REQUIRED TO IMPLEMENT MIG - FLUX CORED MANUAL OR ROBOT BEST WELD PRACTICES. ITS NOT ROCKET SCIENCE, AND OVER THE DECADES I HAVE CONTINUED TO SIMPLIFY MY PROCESS CONTROL, SELF TEACHING / TRAINING PROGRAMS. SO IF YOU HAVE 12 HRS TO LEARN MIG OR FLUX CORED WELD PROCESS CONTROLS - BEST WELD PRACTICES, START HERE:

When I explain to management, engineers, supervisors and technicians that they and their weld personnel need Weld Process Control - Best Practice Training, a common response from many front office personnel is, "our guys don't need this as most of our welders have been with us for 20 years and they are highly skilled". The managers and supervisors will often say this to me while we are watching their weld personnel grind away at poor welds and unnecessary weld spatter, or they may be watching their weld personnel play around with MIG or flux cored weld controls.

It's also never ceases to amaze me that when I do provide the Weld Process Control - Best Practice Training, that i have to insist that the front office weld decision makers and supervisors attend my one day class room, manual or robot, MIG - FCAW sessions. I guess as these personnel don't know what process weld process ownership and weld accountability means. Most dont understand the value of process training, and few understand that to consistently attain the best possible weld quality / productivity means all involved in the building walk the same weld control path.

You would not want to ask any so called experienced MIG welder with 10 + years experience to provide you with;
[] the wire feed/ amps/ travel speed and volt data that a robot will require to make a common 3/16 (5 mm) fillet weld with a 0.035 (1mm )wire.
[] the MIG spray START POINT wire feed, amps and volt data for an 0.045 (1.2mm) wire and 80 - 20CO2.

You cannot implement manual / robot Best Weld Practices without weld process controls.
You cannot consistently attain the highest manual / robot weld quality with out process controls.
You cannot always attain the highest manual / robot weld production without process controls.
You cannot control weld costs, or figure out how to attain the lowest costs without process controls
You can never attain a robot's weld quality / productivity potential without weld process controls.


Consistent, optimum Manual and Robot weld quality / productivity is established through the primary weld decision maker's Best Weld Practices & Weld Process Controls Expertise. This is an expertise that for four dedades has been lacking at most global weld shops. This is an expertise that I have been developing and teaching for decades.

WELD EDUCATION FACILITIES . Process control expertise in 2016, is as far as I am aware still not taught or taught correctly at any global University, College or training facility that teaches Weld or Mechanical Engineers or Weld Technicians. Since the nineteen nineties, my weld Process Controls - Best Weld Practices self teaching - training programs have been available at this web site.


Best Weld Practices - Weld Process Control Resources.



You don't get asked to improve the welds on USA ICONIC consumer products, unless you have weld process control - best practice expertise.


Above, a few of the robot MIG applications that Ed optimized.

 

WHEN INVITED TO ANY GLOBAL MFG. PLANT, IT TYPICALLY WOULD TAKE ME 1 TO 2 DAYS TO OPTIMIZE ANY MANUAL OR ROBOT WELDS AND PRODUCE THE RESOLUTIONS NECESSARY TO ANY OF THE PLANTS WELD QUALITY - PRODUCTIVITY ISSUES. IT WOULD THEN TAKE ANOTHER DAY TO PROVIDE THE PROCESS CONTROL TRAINING, AND I WOULD ENSURE THAT ALL THE RELEVANT FRONT OFFICE PERSONEL WERE INCLUDED..


A FEW OF MY "ROBOT" WELD OPTIMIZATION APPLICATIONS INCLUDE.....


Harley Bike Frames- GM Corvette Bodies and numerous parts - Volvo - Case Truck Cabs and numerous parts- Ford F150 Trucks and Numerous Parts- VW Beetle Seats - Numerous applications for Chrysler - Subaru - Volkswagen - Mercedes - Honda - GE - ABB - Westinghouse - Babcock - Textron Armor Tanks- General Dynamics - Imperial Oil (pipes)- Combustion Engineering - Hydro Aluminum - Hayes Lemmerz Wheels - Fruehauf Trailers - Case - Club Car - Genie - Sky Track - Manatowic - John Deere - Caterpillar - Johnson Controls - DANA - Tower - Flow Master and Monroe Shocks.

IT DOES NOT MATTER IF YOU RESPONSIBLE FOR BUILDING TRUCKS, OIL PATFORMS OR SUBMARINES, AS A MANAGER, ENGINEER OR SUPERVISOR YOU DESERVE TO LOOSE SLEEP IF YOU DO NOT HAVE WELD PROCESS CONTROL EXPERISE AND CAN APPLY BEST WELD PRACTICES, TWO FUNDAMENTAL NECESSARY TO REDUCE YOUR COMPANIES WELD LIABILTY POTENTIAL.

With the common weld processes such as MIG, Flux Cored and
GTAW, and the ever increasing, extraordinary amount of poor and inconsistent weld quality that is produced daily around the globe, the potential for catastrophic weld failures and costly product liability issues dramatically increases each year.




Small weld issues have often creates grave consequences.

A few bad welds on a large weld application could cost many lifes
and create liability costs over a billion dollars.

 

 

2013: $$$ REJECTS - $$$ REWORK - $$$$ GRINDING - $$$ POOR PRODUCTIVITY:

In the industries that utilize the MIG and flux cored weld processes, thanks to engineering apathy and lack of weld management ownership, hundreds of millions of dollars are daily spent on;
[] unnecessary weld rework,
[] unnecessary NDT costs,
[] unnecessary weld rejects,
[] unnecessary weld rework,
[] unnecessary weld cleaning,
[] unnecessary weld meeting
and then add to this the typical
poor or inconsistent weld productivity and you figure out the importance of process control expertise.

 

 



Weld Process Controls - Best Practices expertise
is essential to control & minimize weld costs.

 

SIMPLE WELD COST QUESTION... A MIG or flux cored welder using an 0.045 (1.2 mm) solid or gas shielded flux cored wire wire, works in a weld cell for 8 hours a day. The welder has nothing to do all day but weld pre-tacked parts in the flat weld position. The welds are all 1/4 (6 mm) fillet welds. The welders average arc on time each hour is 30 minutes. In a plant that knows the correct MI - FCAW settings, how much weld wire on average would the welder use each shift? If it takes you more than 3 minutes to figure this out, you will benefit greatly from any one of my process control self teaching programs..

THE USE OF A GRINDER ON MIG WELDS IN A WELL MANAGED WELD SHOP, SHOULD BE AS RARE AS HEARING AN INTELLIGENT COMMENT FROM DONALD TRUMP.

If anyone in the weld industry has doubts about why anyone in this business should be concerned about the overall, poor, global MIG - flux cored weld quality and productivity, they first may want to take trip to my "Bad Weld" section. A section I eventually stopped writing as the evidence was simply over whelming.

You may also want to take a few moments to read about about the extremely poor Self Shielded (SS) flux wire welds that were responsible for millions of dollars spent annually
on unnecessary Chrysler robot weld rework. The poor Chrysler welds were caused by the poor weld wire recommendation from the corporate Chrysler weld engineer who got his weld advice from a Lincoln salesman . And just to show what a real problem we have with poor sales advice in North America, you may also want to read why similar Self Shielded wires were used on CA construction projects that were built over earth quake fault lines. Many of the buildings and bridges that toppled during an earth tremor in North Ridge, California, were welded with Self Shielded Wires and guess where the primary support structures broke. By the way the Chrysler Corporation and the engineering idiots in CA and at FEMA are still many years later still recommending the sad Self Shielded process.

 

Management & the Self Shielded Flux Cored Weld Fiasco.


M
any of the North Ridge, California structures
that collapsed (above), were supposed to be designed to stand up to the anticipated CA seismic quake loads, yet with a few tremors well within the seismic design load criteria, these buildings and many other structures collapsed like a pack of cards. The bottom line with North Ridge, when you cut through all the corporate, design, engineering and political lack of accountability, and weld process ignorance, many of the buildings simply collapsed due to "weld failures" with SS weld wires made by "unsuitable Lincoln, Self Shielded (SS) flux cored wires".
(Note
: Hobart also makes similar consumables)

It should makes any rational person shake their head at the gross weld process ignorance and ineptitude shown in CA. And to make things worse. the world's most inept government organization, FEMA then became involved in making weld spec requirements for construction projects. This is the FEMA that could not make trailers suitable for Hurricane Katrina victims. Of course FEMA with its none weld back ground and no weld process expertise sees no problem becoming involved in weld specification and recommending the SS wires which are still in use in 2016...

 

 

 

2000: The Oil - Nat Gas industry is an industry in which the front office managers, engineers and supervisors responsible for welds, will too frequently be weld decision makers who will lack MIG - Flux Cored weld process control - best weld practice expertise. It's more likely in these industries to find front office weld decision makers stuck in the; "This is the way we have always done it" engineering mode..


WHEN IT COMES TO CONSTRUCTION & REPAIR WELD PROJECTS, FOR DECADES, MOST NORTH AMERICAN REFINERY
MANAGERS & ENGINEERS HAVE BEEN STUCK IN A WELD TWILIGHT ZONE.

The year was 1984. I was asked to consult on some serious pipe weld issues at one of the largest oil refineries in Houston TX. At the refinery, a new section was about to be added. The pipe project required over a thousand pipe welds and I recommended TIG roots and 0.045 gas shielded flux cored fill passes. Those responsible for the weld decisions were in the usual "why change the way we have always done it crowd? after all the refinery was built sucessfully with the Stick weld process back in the 1950s. In the 1980s as you would have found as you will find today in 2016, the refinery engineering and management weld decision makers, too often want to stay in their weld comfort zones, and use the traditional SMAW (stick) or TIG for the pipe fill pass welds. The engineers and managers weld process ignorance and apathy about the use of the gas shielded flux cored process for the fill passes was very costly for this refinery. I figured out that the use of the gas shielded flux cored wires which would have created far superior weld quality (less weld rewor) with weld labor cost savings of approx. two million dollars.


IN THE WELD SHOPS THAT TYPICALLY PRODUCE PIPE / PRESSURE VESSEL WELDS ON CODE QUALITY APPLICATIONS, YOU WILL OFTEN HEAR MANY MIG AND FLUX CORED WELD OPINIONS,
YET FEW OF THE OPINIONS WILL BE BASED ON WELD REALITY:



In the weld report I presented to the senior management at the refinery, I included the following in my report:
"On the subject of the best weld process choice for your new refinery extension, during the weld meetings that I attended with your contractors, project managers and engineers, I hope you are aware that the personnel that were the most vocal against the utilization of the highly cost effective Gas Shielded Flux Cored process, indicated to me that they were the least qualified in the meetings to have an opinion on any weld process
".


Many of the good old boys rarely like
WELD CHANGE.


Give them a 6010 or 7018 electrode and they will build you a refinerary in 2016 much the same as it was origionally built in 1956.

I don't suppose you ever heard in your weld - fab shop,
"WHY CHANGE THE WAY WE HAVE ALWAYS DONE IT"

 








M
anagement and the increased Weld Liabilty Consequences that
is derived from the common front office Lack of Weld Process / Control Expertise.


Every executive in an industry that daily deals with critical weld applications, should ask the following fundamental question. Do the managers, engineers and weld decision makers in our company, daily hold themselves fully accountable for the quality of our products manufactured and do they fully understand the important equipment and processes utilized daily?

.

 

Wheres the stick electrodes?


2006: You would be astonished to find that in the next decade, many global chemical plants, refineries and, power plants will be constructed using SMAW (stick) and the regular TIG process as the primary weld processes. The prime weld procedures utilized to build these billion dollar projects today and in the last three decades were likely in most cases based on the Stick and TIG weld procedures that were first established between 1950 - 1975. How many of the engineers at these projects gave consideration to flux cored and TIP TIG processes that would enable dramatic quality improvements with much lower weld labor costs.

Note: TIP TIG is the evolved GTAW (TIG) process. TIP TIG as either a semi-automatic manual or automated process will in contrast to manual TIG, or automated Cold / Hot Wire TIG, provide many unique weld quality, productivity and metallurgical weld benefits.TIP TIG was invented in Austria by Plasch. I created the TIP TIG USA company and then bought this important process to both N. America and Australia. More info visit ww.tiptigusa.com.



 

DOW CHEMICAL MANAGEMENT FOR
THE LAST THREE DECADES

2016: When it comes to the welds produced in the last decade, there are many large Fortune 500 companies that like DOW have been stuck in a 1960's welding Twi-light zone.


2007: IT WAS EVIDENT THAT FOR DECADES THERE WAS A LACK OF CORPORATE MANAGEMENT AND ENGINEERING WELD PROCESS OWNERSHIP AND EXPERTISE AT A GLOBAL COMPANY THAT SHOULD HAVE KNOWN BETTER. THE COMPANY WAS CALLED DOW CHEMICAL:

I had just visited a plant in which Dow Chemical, one of the USA largest chemical companies had requested that a 304 stainless vessel approx. 3 inch thick and 8 feet in diameter, was to be welded with 1/8 (3.2 mm) diameter STICK electrodes.

Re
member I have been in hundreds of plants and involved in thousands of weld applications and over the years, the "this is the way we did it in the 1950s" is a pathetic approach to large weld applications in which for decades there has een are more viable process choices. The "why change" approach in the engineering department is something I had seen many times with DOW weld applications. What is ironic is this will come as a surprise to many of the DOW senior engineers and managers who would not know a good weld if they tripped over it.

FOR DECADES, WHEN IT WAS NOT NECESSARY, with many of their large scale weld applications, the Dow managers / engineers would insist on the utilization of SMAW (stick) or the very slow GTAW process. These engineers were simply not comfortable or not aware of what they could have attained with either the MIG - Flux Cored or TiP TiG weld processes.

LACK OF PROCESS EXPERTISE ALWAYS HAS A PRICE....For decades many of the DOW senior managers and engineers have on their large construction projects, dramatically increased their companies weld construction costs and reduced the projects weld quality potential.


THE BOTTOM LINE, WHEN RESPONSIBLE MANAGERS AND SUPERVISORS ARE NOT AWARE OF THE BENEFITS OF WELD PROCESS CONTROLS AND THE REQUIRED EXPERTISE OF WELD PROCESS CONTROLS / BEST WELD PRACTICES ON THE APPLICATIONS THAT THEY MANAGE, THEY ARE LIKELY TO INSIST THAT THE APPLICATION BE WELDED THE WAY IT WAS WHEN IT WAS FIRST BUILT A FEW DECADES AGO.

.

 


THE UNNECESSARY GLOBAL MANAGEMENT CONCERN, FOR FINDING SKILLED MIG - FLUX CORED - TIG WELD PERSONNEL:


PICK UP A WELD MAGAZINE OR READ THE BUISNESS SECTION AND BEFORE LONG YOU WILL READ ABOUT SOME IVORY TOWER EXECUTIVE COMPLAINING ABOUT THE SHORTAGE OF MIG - FLUX CORED OR TIG SKILLED WELDERS..

THE WELD REALITY IS THIS:

ANY COMPANY WHO DECIDES TO EMPLOY AN OPEN MINDED, DRUG FREE, ENTHUSIASTIC INDIVIDUAL WITH "ZERO WELD BACKGROUND",
COULD USING MY EASY TO USE WELD PROCESS CONTROL - BEST PRACTICES TRAINING RESOURCES ACHIEVE THE FOLLOWING.

WITH SOMEONE WHO HAS NEVER WELDED, IT WOULD TAKE 4 TO 8 DAYS TO TEACH AND TRAIN ANYONE WHO HAS A STEADY HAND TO MEET ANY CODE PIPE OR STRUCTURAL WELD QUALITY REQUIREMENTS WITH EITHER THE MIG - FCAW OR TIP TIG PROCESS.. View Ed's MIG - FCAW Best Weld Practices - Process Control Resources.



WELDERS, PLEASE DON'T GET UPSET WITH ME ABOUT THE ABOVE STATEMENT. LET'S FACE IT, IF YOU ARE A TRUE WELD PROFESSIONAL YOU WOULD BE AN INDIVIDUAL THAT COULD "WITHOUT PLAYING AROUND WITH THE WELD CONTROLS" OPTIMIZE ANY OF THE COMMON MANUAL OR AUTOMATED WELD PROCESSES ON ANY, ALL POSITION, CODE OR NONE CODE WELD APPLICATIONS. WHEN YOU CAN DO THIS, YOU ARE A WELD PROFESSIONAL. IF YOU CAN'T DO THIS, YOU ARE SIMPLY A WELDING OPERATOR..

MY RESOURCES SIMPLIFY YOUR PROCESS CONTROL AND BEST PRACTICE REQUIREMENTS


IN WORLD WAR TWO, WITHIN A FEW DAYS, THE WOMEN TOOK OVER MANY OF THE MEN'S JOBS, THEY QUICKLY REVEALED A FEW FACTS ABOUT THOSE EXPERIENCED WELDER SKILLS:


Global Universities
- Colleges - Trade Schools and Weld Training facilities
don't typically teach manual - robot MIG - FCAW process controls - best practices, however I developed these programs over 30 years, and they are available at this site for the price of a good meal for 4.

.

.
Ed training ship yard and Imperial Oil welders on process controls - best practices
required with MIG and flux cored when used on all positions, pipe and plate welds.


Left above. Ed training ship yard welders at Aker, located in the Navy Yard Philadelphia. The training was focussed on how to reduce flux cored weld defects and how to optimize the weld quality and productivity without "playing around" with the weld controls.

Middle. Ed providing MIG and flux cored pipe weld training for Imperial Oil pipe welders. Application 16 inch, Natural gas pipe. On right while the pipe welders had a break, Ed then trained his buddy Jesse, (age 11) that with less than an hour of "effective process training", it's an easy task for an 11 year old to produce all position, code quality pipe MIG root welds, and flux cored fill pass welds.



WHEN I AM INVITED TO EXAMINE A COMPANIE'S WELD ISSUES, I FIRST EXAMINE THE EXPERTISE OF THE RESPONSIBLE MANAGEMENT, ENGINEERS AND SUPERVISORS
... OCCASIONALY IT'S LACKING...



With the MIG and flux cored weld processes, it's not uncommon to find the following missing links in most global weld shops that utilize these two important weld processes:

[1]
Lack of process qualified weld supervision, engineers and management.

[2] Lack of management - engineering weld Process - Equipment Ownership.

[3] Lack of the establishment of weld uniformity and lack of Best Weld Shop Practic
knowlege.

[4] Lack of the establishment of effective Process Control Training programs that lead to the best possible weld quality
- productivity at the lowest weld costs.

[5] Lack of management, engineering and supervision understanding of their real weld production potential or for that matter the real costs of the common daily welds produced.

[6] Either the lack of, or
inappropriate weld job descriptions for all those involved in the weld shop decisions.

Perhaps it's time for the Captains and Engineers of the weld industry to roll up their sleeves, rise up from their computers and step past that glass wall into the weld shop for more than five minutes at a time. While in the shop, take a look around and ask this simple question. "What makes this weld shop better than a good weld shop that was around in in the 1970s"?


Wow!...I now sell MIG weld gas mixes and weld equipment.
Boy this is better than my last sales job at the used car lot.

My real world MIG Gas Facts.

 


There are many managers, engineers and supervisors that might want to take note: "weld process & weld equipment ownership", does not start with the salesman thats just bought the donuts in, or with the "experienced" welders on the weld shop floor".


In th



AS WE HAVE A GLOAL EPIDEMIC OF UNNECESSARY WELD QUALITY - PRODUCTIVITY ISSUES, I CANNOT SAY THIS TOO MANY TIMES:

There are many managers, engineers and supervisors that might want to take note.. Weld process optimization will come from weld process / equipment ownership by those responsible in the Front Office
.

THE GM MANAGEMENT LACK OF WELD OWNERSHIP FIASCO....In the 1980's, Ed was asked by inexperienced General Motors management / engineers to visit one of their Michigan plants to provide weld quality and productivity improvements. This was one of those plants in which the plant managers, engineers and supervisors spent their days either in front of their computors or in endless useless meetings trying to put out the weld shop fires. In this plant as with most auto - truck plants, the GM managers and engineers lacked the ability to make weld decisions that had a positive impact for the manaul / root weld production in their plant. It should be no surprise in this situation to find that the vast majority of the daily weld decisions were left to the weld personell on the shop floor, remember those guys, the ones that daily "play around" with the MIG / robot weld controls.


The following paragraph is from a weld report that I provided to GM managers, it likely immediately ended up in the waste paper basket.

"For those managers that like to leave weld issue resolutions to the weld personnel on the weld shop floor, take note. As any weld manager or engineer should be aware, the robot welds on your cars and trucks have tremendous weld quality, liability, productivity and cost consequences. Therefore an important logical responsibility for the managers and engineers involved with the manual or robot weld process is to take "OWNERSHIP AND RESPONSIBILITY of the equipment and processes" that can impact those welds. The process controll control education takes approx. one day, therefore it's irresponsible that your front office weld decision makers would lack this expertise.

ps: I know at the above GM plant, that my weld report and proocess control views had no impact with the senior managers and engineers involved, which was no surprise to me, after all if these personnel were going to change, the whole GM Corporate Engineering Management Expertise and Culture would also have to change.

 



.

2000: INSTEAD OF USING WELD PROCESS CONTROL - BEST WELD PRACTICE EXPERTISE. MANY MANAGERS AND SUPERVISORS USE A DIFFERENT CRUTCH EACH MONTH..

It's common in global, large weld shops, to find managers who feel good about their newly qualified Six Sigma Engineers - Technicians, or that they are especially satisfied with their recent implementation of the latest Lean Manufacturing craze from weld process confused companies in Japan or Europe. And of course, lets not forget all the time and money that these same managers may have put into their efforts to attain or maintain that popular, and ISO Approval, which from a weld perspective has useless rules, logic and regulations established by one of the world's most inexperienced Bureaucratic Organizations head quartered of course in Europe.

Logical weld managers - engineers and supervisors should never stray away from a simple fact. To consistently attain optimum weld quality at the lowest weld costs has never required Black Belts, White Shirts and black / blue Ties or some Lean Mfg fad, and it's never required the costly useless ISO Standards. Consistent optimum weld quality and productivity will be derived if the one person who daily makes the manual / robot weld decisions has the necessary Weld Process Control
and
Best Weld Practice Expertise.
And management cannot ensure that they have that process expertise if they don't know what the bloody expertise is..


IT COULD BE 1986, OR IT COULD BE 2016. FOR MOST GLOBAL WELD SHOPS, THE MIG - FLUX CORED PROCESS CONFUSION, MYTHS AND PROCESS BS NEVER CHANGES.


During 201
6, many weld shop managers will decide to purchase that overpriced pulsed MIG equipment for their carbon steel and alloy steel welds. I wonder how many of these managers will be aware of the primary pulsed MIG equipment weld issues and it's Achilles Heel which have not changed for almost three decades.

If you are one of those rare indiviuals that does not like to throw money out of the weld shop window,
w
hen you have a moment, visit the Pulsed MIG Welding Section at this site. In the Pulsed MIG section, you will find a lot of interesting weld information about the extensive global sales BS that for decades has surrounded the unnecessary pulsed MIG process and it's equipment for steel welds.

For those interested in providing cost effective, optimum quality MIG and Flux Cored welds, it's important that any weld decision maker;

[1] has the ability to sort out the weld salesmanship influence from the weld process reality,

[2] has attained weld process control and best practice knowledge from
"qualified, unbiased" sources,

[3] has the ability and desire to take process - equipment ownership,

[4] has the weld process control ability to train and implemnt cost effective Best Weld Practices.



 


Visit the most comprehensive weld process control -- best practice training data available on the regular MIG, Pulsed MIG, Flux Cored processes.

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..


You would think that with construction projects and buildings designed to with stand the frequent California earth quakes, that an engineer involved should have certain weld quality expectations for the structural steel welds made on the majority of those buildings. Check out my California, Self Shielded flux cored weld farce article, and the resulting costly weld disaster for CA taxpayers.

The Northridge Earthquake Lincoln - Federal FEMA Weld Fiasco



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2007: EVERY DAY THAT CITY, STATE & FED GOVERMENT WORKERS ALONG WITH ARCHITECTS - DESIGNERS - ENGINEERS - PROJECT MANAGERS AND INSPECTORS ALLOWED THE USE OF THE "SELF SHIELDED FLUX CORED WIRES" TO BE USED ON THEIR PROJECTS, WAS A DAY IN WHICH ENGINEERING PROCESS IGNORANCE AND STUPIDITY HAD TAKEN OVER FROM WELD AND MECHANICAL ENGINEERING SANITY.

2007. THE SELF SHIELDED FLUX CORED HAVE ALWAYS SINCE THEIR INTRODUCTION BEEN THE WORST POSSIBLE CHOICE FOR PROJECTS IN WHICH WELD AND PART QUALITY ARE IMPORTANT.

The selection of Self Shielded (SS) flux core wires is common around the globe when constructing steel structures, yet the weld reality is these weld consumables should never seriously be considered for any code quality welds. Engineers and managers who are often too busy to read my Welding Books, or read the Flux Cored sections of this site, will however have the time to get weld process advice from a sales rep or from the companies who make the SS weld consumables. And if a person does not mind BS the best process to start with in the weld industry is the SS process.

The wide use of the SS wires is again another example of lack of weld process expertise and a lack of management / engineering weld process ownership. For more info on why you don't use these wires, read below.

The North Ridge SELF SHIELDED FLUX CORED weld farce, with the political / corporate BS lies, deceit and donations would have made a good Tom Cruise movie:

Note: IN 2106 THE SS WIRE ARE STILL BEING USED ON BUILDINGS
SUBJECT TO POSSIBLE EARTH QUAKES... God Bless the Good Old USA...


READ ABOUT THE LINCOLN SELF SHIELDED FLUX CORED WELD WIRES AND THE UNUSUAL LINCOLN FEEMA RELATIONSHIP. THEN FIND OUT HOW THESE WIRES INFLUENCED THE STRUCTURAL WELDING DISASTER AND REPAIR FIASCO THAT OCCURED DURING AND AFTER THIS CALIFORNIA EARTH QUAKE?


If you are a weld manager or engineer and you accept your responsibility to ensure that the weld decision makers in your organization understand what is process - equipment - consumables BS, and what is real. I would recommend that you consider providing your weld work force with one of my process control training programs, necessary to optimize the process / consumables utilized.

The weld industry daily pays a hugh price for weld process, weld equipment and weld consumable ignorance;

[a] the weld shop daily weld scrap will be expensive,
[b] the weld shop daily weld rework will be costly,
[c] the weld shop daily weld productivity will rarely be at it's potential,
[d] the weld shop weekly weld team meetings will be time wasting, frustrating and fruitless,
[e] the weld shop employee moral will be low,
[f] the companies weld failures and liability consequences could be dramatic.

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"PLAY AROUND." THE TWO MOST COMMON WORDS USED IN GLOBAL WELD SHOPS, AND TWO WORDS THAT HAVE ALWAYS BEEN A GOOD INDICATION THAT SOMETHING IS SERIOUSLY WRONG:

The MIG process is the world's most widely utilized weld process and a process which is more than 60 years old. With this old, and simple weld process, it's not reasonable to watch any weld personnel play around with either their MIG & flux cored weld controls.

When people play around with a process that process is rarely optimized. Any decent engineer, manager, supervisor or technician that is involved with MIG or the flux cored process would search for the expertise so this nonsense will finally end.





When the Big Three and their Tier One managers and engineers, don't understand Robot MIG Best Weld Practices and lack the ability to set Robot Weld Process controls,
it should be no surprise they end up producing truck frames MIG welds like this.

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Major auto companies or Tier suppliers, the process expertise is often lacking.


An ironic point: A Big Three USA Auto - Truck company had to get these truck frames, robot welded by an international Tier one supplier. One prime reason why the Big Three companies typically got someone else build their major welded parts, is the BIG Three managers and engineers typically lacked the robot and MIG weld process control expertise necessary to manage and optimize the robot MIG welding lines at their plants. As the above Tier One, robot MIG frame welds indicate, this Tier One supplier also employed managers and engineers that lacked the same process control expertise as their Big Three customer.





For those that want to know what management and engineers in the automotive and in the oil industry have in common, click here.






To optimize any robot MIG weld quality & productivity,
I created a unique Seven Step,
Robot Weld Process Control - Best Weld Practice Program.

 




NO MATTER WHAT THE INDUSTRY IS, AS LONG AS THEY ARE USING MIG AND FLUX CORED, YOU WON'T HAVE TO LOOK FAR TO FIND MANAGERS, ENGINEERS AND SUPERVISORS CAUSING EXTENSIVE WELD QUALITY - PRODUCTIVITY AND COST ISSUES.




Question:
What do the majority of ship yards and auto - truck plants and construction equipment manufacturers have in common?

Answer: These industries frequently employ "Hands Off" managers, engineers and supervisors that are not aware of the requirements and benefits from weld process controls expertise, and typically they will lack weld process ownership.

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In over 90% of global ROBOT MIG weld applications,
the robot weld production efficiency is rarely attained.


1986 to 2016, WILL THIS NONSENSE EVER END?: In the majority of global manufacturing facilities that produce MIG - FCA welds, both manual and Robot MIG weld best practices and process controls are rare. At most of the plants that use MIG welding robots, the robot weld efficiency, robot weld costs and real robot weld production potential was poorly understood by the plant's managers, engineers, supervisors and technicians. Robot times, weld speeds, robot downtime, robot weld rejects and rework are factors that influence robot weld efficiency. In the 1000 plus global manufacturing plants that I visited in thirteen countries in the time period 1985 to 2010, I found that the plant's daily "robot weld efficiency" was typically less than 60%. In 2016, it's a sad reflection in the global industry that little has changed.


WHILE COMPANIES CONSIDER PURCHASING MORE COSTLY ROBOTS TO INCREASE THEIR WELD PRODUCTION, it's a sad weld reality, that few managers or engineers involved with the purchase of MIG welding robots;

[a] will understand how to maximize their existing robot weld quality - productivty potential,
[b] will understand the real cost of a simple 3/16 (5 mm) fillet weld, which is a common weld found in most auto - truck plants.
[c] will provide their employees with the process training necessary to correct weld resolutions when weld issues occur and to attain maximum robot weld efficiency.


USUALLY WHEN A WELD PROCESS IS NOT OPTIMIZED TO MEET IT'S FULL WELD QUALITY OR WELD PRODUCTIVITY POTENTIAL, YOU WOULD THINK THAT WOULD BE A MESSAGE TO SOME MANAGER, ENGINEER OR SUPERVISOR, THAT IT'S TIME FOR CHANGE:

2016: Perhaps the billions of dollars spent annual in the auto / truck industry on warranty claims, recall costs and rework has something to do with the incorrect management - engineering philosophy utilized, and the lack of ownership and expertise by the engineers and managers responsible.

In North America, Europe and Japan, thanks to ignorance and poor manufacturing practices preached for decades by confused inexperienced senior manufacturing executives, the auto and truck industry has over three decades, developed into any army of ineffective white collar "hands off managers and engineers". You can identify these personnel that lack the ability to take ownership of the parts, equipment. processes and personnel that they daily work with.

IN THE MAJORITY OF LARGE GLOBAL WELD DEPARTMENTS YOU ARE LIKELY TO FIND SOMETHING LIKE THIS....

THE COSTLY HUMAN QA / INSPECTION DEPT RESOURCES ARE UTILIZED FOR FINDING RATHER THAN PREVENTING WELD DEFECTS, THIS INDICATES THAT IN THE PLANT THAT THERE IS SOMETHING LACKING IN THE WELD PROCESS - APPLICATION KNOWLEGE WITH BOTH THE QA AND PLANT MFG. MANAGEMENT.

WHAT'S LACKING? FIRST THE INABILITY OF WELD DECISION MAKERS TO EVOLVE WITH PROCESSES SUCH AS MIG - FLUX CORED - TIG, PROCESSES THAT HAVE BEEN AROUND FOR DECADES. ALSO WHAT'S LACKING IS THE KEY WELD DECISION LACK OF WELD PROCESS CONTROL - BEST WELD PRACTICE EXPERTISE.

In many global weld fabrication organ
izations, the primary function of the QA department inspection personnel is after the welds are complete, find visual weld defects and document & report those defects. Filling out paper work does not improve weld quality and reduce the costly weld rework. An important question that could be asked of any plant Mgr, Manufacturing Mgr. or QA Mgr.

[a] Would it be more cost effective for your organization if the technical people resources in your plant were focussed on "preventing" rather than finding weld defects?


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Every engineering, QA or plant manger involved in welding should ask the following fundamental question....

WHY DO WE HAVE OUR COSTLY QA DEPARTMENT RESOURCES FOCUSSED ON FINDING WELD DEFECTS, RATHER THAN TRAINING ALL INVOLVED EMPLOYESS WITH THE PROCESS CONTROL - BEST PRACTICE WELD EXPERTISE THAT WILL PREVENT WELD DEFECTS?


To overcome their manual or robot weld issues, many global fabrication shops will often focus on trying to reap benefits from their costly, bureaucratic, mostly ineffective European, ISO Manufacturing Standards, or they may be busy implementing another lean manufacturing fad from Japan.

Many in the weld business are not aware that while there are some things to be admired in Japanese / European weld mfg practices, major corporations such as Toyota and Honda and VW had for decades like the BIG Three in Detroit, also produced pathetic robot auto - truck MIG welds.

To add to the global weld industries sad state and process confusion, the majority of major companies that employ QA managers, will not be aware that they have created costly, bureaucratic departments focussed on "finding / reporting" weld defects and filling out endless paperwork, rather than a department that has the human resource expertise to optimize the weld quality and prevent weld defects.

AS I HAVE BEEN SAYING FOR FOR AT LEAST THREE DECADES,

THERE IS GREAT OPPORTUNITY FOR DRAMATIC WELD COST SAVINGS THROUGHOUT THE GLOBAL WELD INDUSTRY. HOWEVER TO GENERATE THOSE SAVINGS, WELD SHOPS NEED MANAGERS AND SUPERVOSORS THAT UNDERSTAND THE PROCESS CONTROL AND BEST PRACTICES REQUIREMENTS FOR PROCESS OPTIMIZATION:

To resolve either your manual and robot MIG - Flux Cored weld production and quality issues, you would in less than 20 hours attain the info you need from anyone of my process control books or from my training resources.

Em's Process Control Best Practice Books - Training Resources.



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DONT GET PISSED OF AND TRY TO SHOOT THE MESSANGER.... I hope my personnel views and this web site provide a clear message which I know i have repeated at least 1000 times. I am also aware that the consistent message may be uncomfortable for many managers and engineers that have to daily deal with the common global MIG, flux cored and TIG weld issues, by the way issues that have changed little in five decades.

The reason why I repeat the process message so much is when something important in an industry does not change for at least five decades, to create that change you know someone will have to hammer away and keep repeating what both the problems and solutions are.

This web site has over a 1000 pages of common MIG - FCA weld issues, and more importantly this web site provides extensive weld solutions and the self teaching / training process control - best practice resources . I am well aware that the information at this web site will be lost on weld personnel that dont visit sites like this and instead they will rely on the weld sales personnel for weld advice. Its also lost on those individuals that simply view welding as a source of their pay check. For those few that do visit this site, I strongly recommend you take a look at my process control Best Practices resources.


AN INDUSTRY THAT RELIES ON OVERWORKED POORLY TRAINED ROBOT TECHNICIANS, IN AN INDUSTRY THATS CRYING OUT FOR A FIX YOU COULD SAY THAT 30 YEARS AGO OR SAY IT IN 2016:

The too common, hands off managers / engineers who leave the robot weld issues to the lesser paid, lesser educated people on the shop floor, have resulted in a global robot MIG / Resistance weld industry in which in the majority of plants you will frequently find over worked, under trained robot technicians. The process inexperienced technicians are too often required to take ownership and responsibility for their plant's daily robot weld quality and productivity issues. These poor guys will typically work 60 - 80 hrs a week and will often feel isolated from the front office managers and engineers who manage a game of golf on the weekend when the robot techs are struggling with the never ending changes in the plants robot cells. A major reason why the technician struggle with their robot weld resolutions is thetechnician have never received Robot Process Control - Best Practices training.








If you are in the weld industry, you will want to ignore weld advice and
recommendations from the leading
Japanese Auto & Truck companies.

 





In dealing with Japanese auto - truck companies such as Honda and Toyota, I often found that these plants had rarely employed a weld process control expert, instead they typically relied on an inexperienced Weld Team or attained weld advice from Japan engineers. The weld specs and weld advice they provided simply revealed that process ignorance. This was true 30 years ago and true today in 2016, except today we can now include the same BS with the majority of global major auto - truck companies.

However in my visits to the Japanese car / truck palnts, I did find one subtle difference between the North American and Japanese approach to weld mfg. In general I found that the Japanese management appeared to have a little more interest in the "process / equipment ownership". So with these managers, if i was in the plant on the weekend making the changes, instead of playing golf on the weekends like some of their USA counter parts the Japanese managers would end up in the plant looking over my shoulder. I would also say that because they were in the plants the Japanese managers or engineers would in most instances have no influence on the robot weld resolutions required, however at least they were interested.

FROM HARLEY TO GM OR TOYOTA.. WHEN A COMPANY FIGURES IT NEEDS A "WELD TEAM" TO DEAL WITH IT'S MANUAL / ROBOT WELD ISSUES, THIS SIMPLY MEANS THAT COMPANY HAS NOT HIRED A WELD EXPERT.





WELD FUNDAMENTALS. IT HELPS IF A MANAGER CAN QUICKLY FIGURE OUT THE COSTS OF THOSE COMMON MIG - FLUX CORED WELDS:

The most common MIG welds found in most global auto - truck robot cells are
3/16 - 1/4 (4 - 6 mm) fillet, lap and butt welds. From the hundreds of plants I visited,
I came to the conclusion that it was extremely difficult to find a manager, supervisor or engineer that in less than 5 minutes could tell me the real cost of their most common robot or manual MIG welds.

Why would any company want to purchase more costly robots to improve their productivity, when the managers and engineers responsible for those robots typically lack the weld process - best practices knowledge to control the robots and ensure the robots are achieving their full weld production / quality potential?





JAPAN VERSUS NORTH AMERICA. IN GENERAL BOTH COUNTRIES HAVE MAJOR CORPORATIONS THAT LACK WELD PROCESS CONTROL - BEST PRACTICE EXPERTISE, HOWEVER THERE IS A SLIGHTLY DIFFERENT APPROACH TO THE WELD MANAGEMENT:


When it comes to joining two pieces of carbon steel in auto - truck part plants, the typical North American manufacturing manager will frequently be a "fire fighter", forever chasing the weld production fires, yet never finding out the root cause of why those weld fires started. In contrast, the Japanese trained managers typically shows a little more interest in finding the root cause of their process or equipment issues. In most instances the Japanese manager will lack the expertise necessary to find out the optimum weld solution, however the fact that the underqualified manager is prepared to spend some time on the weld shop floor, (even on weekends) and has some interest in the equipment - process ownership, will usually have beneficial results and it certainly helps with the weld shop moral.


2000: Why the most naive, and inexperienced industrial nation in the world, was always Japan.

For decades after the second world war, Japan only used straight CO2 for MIG welding as they had limited acess to argon. If you have welded with straight CO2, you will know the erratic, globular weld mess it produces. The Japanese tried to compensate for the CO2 with building some of the worse electronic MIG equipment that was ever produced. Even in 2014 I still grimace when I see a Panasonic MIG power source.


Anyone who has had to work with Japanese welding robots and MIG equipment would be aware that during the last two decades, the Japanese had an undaunted belief in their Japanese built, costly, MIG equipment that was typically loaded with useless, ineffective electronic bells and whistles. It was amazing to me that when the Japanese built car and truck manufacturing plants in North America, they would typically demand that only Japanese robots, Japanese MIG equipment and Japanese MIG weld wires should be used, (talk about bringing poor quality coal to Newcastle). The Japanese management who knew less about welding than the American management, believed that only their rising sun, robots, weld equipment and consumables could join two pieces of carbon steel together in North America.

2000: If the Japanese managers in North American facilities truly understood welding and evaluated the Japanese products frequently forced on them, they would find that in most instances the Japanese weld / robot equipment and weld process performance was inferior to alternative products made outside Japan. Experienced Japanese weld managers would also be aware that during the last two decades, a prime root cause of their auto / truck robot welding issues was Japanese built, poor performing MIG welding equipment. To
read more on Japanese robots and their pulsed MIG welding equipment issues, visit my MIG - Pulsed MIG and Robot sections of this site.

Note: In 2011, it's true that finally the electronics in Japanese built MIG equipment are now making decent welds, the point is with MIG process control expertise, the CV MIG weld equipment developed in the USA in the 1960s could produce the same weld quality and productivity, and this CV equipment has always been much less costly and far more durable.






Em Set the robot welds on the above Genie equipment and was Weld manager in the ship yard shown. She also established optimum robot welds on the Club Car golf cart that she used in to get around the Aker shipyard. As the Aker (short term) ship yard weld manager, Em also trained the Aker weld personnel to attain flux cored process optimization. The flux cored improvements on the oil tankers saved Aker over 5 million dollars annually on reduced ship weld rework.




Many North American manufactures followed this road south. When the managers and engineers lacked the ability to meet their daily robot MIG weld quality - productivity objectives, the company executives, (not worried about retaining jobs for their employees in USA) did not think twice about sending the robots and parts to be welded, to either Mexico or China.


Executive Decisions:

[]
As few robots attain their full production and quality potential, many auto - truck plants will purchase more robots than they need and dramatically over spend on the weld equipment and fixtures.

[]
Thanks to apathetic engineering management, most auto - truck plants don't produce robot welded parts in accordance with the part design dimension tolerances

[] Thanks to a general lack of understanding of optimum MIG weld best practices, the majority of auto - truck plants don't build MIG weld fixtures that will enhance the the robot weld quality and production potential

[] Unnecessary robot down time and weld rework and questionable weld quality concerns are too often influenced from inexperienced management and engineers who do not understand the requirements of weld process ownership.

[] The reason training programs are rarely effective, is the auto - truck plant management typically don't understand the Best Robot Weld Practices and Robot Weld Process Control training programs which should be provided to their employees.

[] The majority of auto - truck plants management and engineers would struggle to work out the real costs of their most common welds.

When you have the above situations, you will have managers / engineers that may make the decisions to shut down the USA or Canadian, robot MIG weld lines and sweep the weld manufacturing quality or productivity problems under a large Mexican rug. As the North American plant workers say adios amigo to their jobs, those robot welded parts will then be shipped off to Mexico.




While the big three companies had no shortage of highly educated, highly paid engineers, one could ask how effective that engineering education was, when the guys had to deal with robot MIG weld issues.

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IN MOST OF THE BIG THREE AND TIER ONE PLANTS THAT I HAVE VISITED, THE MOST DIFFICULT THING TO FIND WAS A MANAGER OR ENGINEER WHO UNDERSTOOD THEIR ROLE, RESPONSIBILITY AND ACCOUNTABILITY IN THE REQUIREMENTS NECESSARY TO CONSISTENTLY ATTAIN OPTIMUM ROBOT MIG WELDS AT THE LOWEST POSSIBLE WELD COSTS.

 


Billions of dollars are lost each year from manufacturing companies that employ "inexperienced car and truck mfg management". During the last decade, the big three and their Japanese and European competitors have lost billions of dollars each year in unnecessary product warranty, unnecessary recalls, unnecessary rework, and from poor weld productivity. How many managers or engineers in the auto - truck industry start their day by looking in a mirror and feeling a twinge of guilt about their inability to improve their plant's daily weld quality and productivity? How many of these guys are even aware of their lack of process ownership or the real cost of the welds they daily produce?

Designers also add to the daily weld issues. It's a sad fact that the majority of designers of auto - truck parts, will typically show minimal interest or have any expertise with the common weld processes used to join their parts. It's not uncommon to find designers in car plants who daily on there way to their office will walk past reject pallets or weld rework bins filled with their parts, yet these guys would not stop and take a minute to find out if their design had any influence on the required weld rework. Without question, designers could ensure less robot weld quality - productivity issues if they understood the compatibility of the automated weld process and consumables used on their components. All designers of welded components have a responsibility to understand the common weld processes used to weld their parts. While these guys don't have to know how to weld, I would recommend that they read my Management and Engineers Guide to MIG book. I also believe my advice here is a wasted effort on my part. After all, the majority of designers and their profession have shown no interest in MIG welding for decades.

Those car - truck "shop floor workers" that want to retain the good paying jobs in the USA, also have a weld process control responsibility.

What about the workers: How many times will a worker in a car or truck plant, without a side glance, daily walk past those over flowing weld reject - rework bins on there way to their lunch rooms. On the lunch room tables the workers may find an old "People or Playboy" magazine, (its a rare event to find a weld magazine). Also in the lunch room, on the notice board there may be a report that shows the daily, poor robot weld quality and productivity, or perhaps there will be a glossy brochure on the companies annual warranty and recall costs. How many of these workers that make a good living wage, will reflect on their lack of expertise and their influence or role on the plant's daily weld quality - productivity. To retain jobs in North America shop floor workers need to have a greater voice and input into the quality and productivity of the components they derive a living from. The first thing shop floor workers should demand, is the process control, best practice expertise training that they lack. As management is not aware of what they need someone on the shop floor may have to spaek up and point out that the robot issues have nothing to do with the robots, the issues are people and the people include the management, engineers and workers.

Confused HR Personnel will frequently request that the newly hired weld engineer should have robot, press and paint shop experience. This too common multi task request in a job description for someone to solve robot welding issues, is a reflection of the ignorance and lack of understanding of both management and HR personnel for the expertise necessary for someone to control and to optimize a major process. HR departments take note, there are no multi process experts in North America and it's likely there never will be, and until your industry insists that engineers roll up their sleeves, if you want results hire a technician who at least has hands on experience and pay him the same wage you would pay that engineer.




Poor or No Job Descriptions, and WELD CAREERS:

The following is a typical Want Add for an Auto - Truck plant position:


Wanted. We are looking for a weld engineer or technician with robot, MIG / Resistance and Laser weld experience. You must also have Paint shop and Press shop expertise, (if you also have electrical expertise this is a plus)
The remuneration depending on your expertise will be $50 - 65K per year. Note, we are sorry that this is the same pay rate we provided two decades ago. We provide one whole weeks paid holiday after two years. Also as you will be the plant expert with these processes. our management will expect you to work 60 - 80 hrs a week including most weekends. Please note, as a privileged, salary employee you will not receive overtime pay, however you will have use of the executive washrooms.

You could laugth at the above, however it's not far from reality. When the ignorant, HR managers who are typically influenced by the ignorant plant and manufacturing managers, place a multi-process expert job description, someone with their feet firmly planted, needs to sit these sad creatures down and explain. The reality is in manufacturing we have never had no multi-process control experts. I have taken 50 years to learn about MIG process controls and continue to learn. You can spend a lifetime with any one of the important processes used in the auto plants. To attain process optimizations at the lowest costs requires process control specialization and this specialization on paint, press shops or welding should take two to four decades to master. The learning curve for manaul and robot weling is dramatically reduced, if the weld process control resources available at this site are provided.



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THIS IS WHAT MAKES A USA
DREAM WELD TEAM.

MANAGEMENT AND THEIR INFAMOUS ROBOT WELD TEAM?


Of course, if management ensured that they and everyone involved with the welding robots and the welded parts was given the correct training so they were qualified to do there job, then a robot weld team would not be necessary. Inexperienced manufacturing management and the engineers responsible for high volume, welded parts will typically have a long list of issues that are generated in each robot weld cell. For those companies that can't seem to achieve consistent, optimum robot weld quality and productivity, the management will typically take a "team approach" to try and address the robot weld quality or productivity issues, which if you think about it, is also a good way for the management to water down and spread around their robot / process ownership and responsibility. In these common, global robot weld manufacturing circumstances, it typically takes a diverse team to try and address some of the issues that impact both the robot weld quality and productivity.

The robot weld team may require the manufacturing manager who typically lacks the ability to make the parts in accordance with the welded part design dimensional specifications. The production manager will of course be necessary on the team, as his daily production is all over the place. Lets not forget the maintenance manager, this guy will be needed for those poorly designed fixtures and the poorly maintained robot cells. Of course, the QA manager will head up the team, as he will need to pontificate about the inconsisten and poor weld quality, you all know this QA guy who knows how to find weld defects but dies have a clue on how to prevent them. If the management can spare the over worked, underpaid, head robot technician, he will of course be on the team, his role will be to bore the team with all the diverse issues that occur in each robot cell. And last but not least, the team should have at least one of the robot operators who will give his slant on why the robot operators daily struggle to meet the robot weld quality and production goals.

One could ask this simple question, If that weld team was to be fully effective, would it help if the team members understood the "fundamental requirements" of Robot Best Weld Practice and Robot Weld Process
Controls, so they could all walk the same logical path to the necessary corrective weld solutions.

. >

Review Ed's Management & Engineers Guide to
MIG book and process control training resources.



What's the purpose of that
engineer supervisor or manager?



FROM THAT HANDS OFF, CELL PHONE ENGINEER, WHO OFTEN PROVIDES LITTLE VALUE TO HIS COMPANY:

In Ford - GM and Chrysler plants, when the welding robots are creating weld problems, the majority of hands off engineers when notified will often be found at their computer. To resolve the robot weld issue, they typically will reach for a cell phone to call the lesser paid, lesser educated technician.

TO ANY INDUSTRY THAT HAS TO RELY ON TECHNICAL AND WELD ADVICE FROM A SALESMEN:

When these engineers and managers need advice about the fifty year old MIG process problems in their shop, with no shame they will pick up a phone and ask a weld salesman who may have a degree in English or Music for a resolution to the weld issues.






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THE GLOBAL LACK OF WELD MANAGEMENT RECOGNITION
for Weld Process Controls - Best Weld Practices expertise".



For decades, the global MIG welding industry focused on "welder skills" rather than on welder process control expertise. This is the prime reason you will find in the majority of weld shops, both manual and robot MIG weld personnel "playing around" with their 60 year old, hardly changed, MIG weld controls.



A lack of global weld logic.

HOW ABOUT GOING ON A "WELD MANUFACTURING OFFENCE"?

Joe, as the manager of this plant, I want to see you go on the "Weld Manufacturing Process Offense", which by the way has to be better than forever living with the costly weld results from your daily, "Hands Off Management Defence".

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SEPT. 2006: I WAS ASKED TO RECTIFY A ROBOT, MIG WELD POROSITY PROBLEM. THE WELD ISSUE WAS ON STEEL PARTS FOR A JAPANESE TIER ONE SUPPLIER. THIS SUPPLIER MADE PARTS FOR BOTH SUBARU AND TOYOTA.

The multi-robot cells were used to MIG weld galvanealed steel suspension parts. The robots welded on average 600 parts per day. The final weld assembly cycle time for each part was approx. three minutes forty seconds, with a weld repair rate of approx. 20%.

Of course there was no time to make changes to te robot cells during the week, so I was asked to make the changes on the weekend. As I made the many weld changes to the robot, I was amazed to find that the Japanese company president, and for gods sake, his "chief operating officer" stayed with me in the robot cells on both the Saturday and Sunday. I guess the operating officer wanted to find out what he was getting for my small fee of twelve hundred buck a day.

The confused Japanese robots were from Motorman and the weld power sources utilized were produced by Panasonic. From my past experiences this was a poor Japanese equipment combination. The none pulsed, five year old Panasonic power sources were erratic, they were also not calibrated, and they produced poor MIG arc weld characteristics. Unfortunately I had to work with the poor tools supplied, so in a ten hour period that involved new robot programming moves and extensive weld process improvements, I was able to get rid of the weld problems that were causing the weld rework. For my small fee, I also gave the plant an unexpected bonus by lowering the robot weld cycle time from three minutes forty secs, to one minute forty seconds

The dramatic cost reductions and weld quality and productivity gains bought a big smile to both the company president and chief operating officer who assured me that my apathetic $2500 check, (they saved over $300,000 annually or 3 million for the contract) would be in the mail within a week. In the past decades, I have provided similar dramatic weld quality - productivity improvement to many of the tier one suppliers, however while at the plants, I rarely saw any interest from the plant management or engineers for my robot and manual weld resolutions.

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In the USA, we did not just loose jobs to NAFTA and the numerous lower wages countries, we also lost a tremendous amount of good paying USA manufacturing jobs due to ignorant, self centered, greedy politicians, and Fortune 500, manufacturing, management and engineering, ignorance and incompetence.




The 20 million plus dollars Chrysler Management fiasco.





Talking about manufacturing management icompetance, in the nineteen nineties, in a period of less than 18 months, Chrysler corporate and plant management lost over 14 million dollars from a new welding robot line. This line was located at it's prime Mini van stamping facility in Ohio.
The robot weld line was designed to weld Neon cross-members. From the day it went into production, this line never made more than 50% of it's daily robot weld production goals and the daily robot weld rework was 100%. The robot welds were made with Lincoln, Self Shielded, (SS), Flux Cored wires.

The frustrated, Chrysler stamping plant manager had requested Lincoln engineers provide help with these welds. Eventually the manager gave up on the Lincoln engineers and requested my assistance. In less than 3 days of process evaluation, I came up with a weld process solution to fix all the welding issues, most of which by the way were caused by the poor choice of the the Lincoln SS wires.

The Lincoln SS wires were chosen by the Chrysler corporate welding engineer. For self preservation reasons the Chrysler corporate weld engineer declined to admit that he had made a mistake when he selected the world's worst weld process and consusmables that were better suited to welding chicken coups than welding costly car parts.

I recommended to the plant manager that to convince that process ignorant Corporate engineer of the folly of his process selection, that we do the robot welds with MIG. The plant manager gave permission. I then produced the sample parts providing a dramatic increase in the robot line weld productivity, and with no weld rework required. I had the parts weld and part strength tested by the largest testing agency in Detroit. They reported that the welds and parts met the design requirements and had no defects.

For the Chrysler engineer to accept my process changes would have been an indication that he was responsible for the multi-million dollar robot weld issues. He argued with his corporate peers, (the blind leading the blind) that changing to MIG would be a mistake. They went back to using SS wire and a few months later the the higly paid Chrysler management team made a gutsy engineering decision. The Neon stampings and the new robots were loaded into trucks and shipped out of sight south to Mexico.

The reason for the robot line shut down and loss of USA jobs, was not the cheaper Mexican labor, the reason was the Chrysler management and engineers involved with the project;


[a] lacked the ability to design parts suited for robot welds,
[b] lacked the ability to build parts to their own design tolerances,
[c] lacked the ability to make rational weld process and consumable decisions,
[d] lacked the ability to establish effective robot weld best practices - process controls.
[e] lacked the ability to stand up to the weld engineer who's ego and lack of expertise was the root cause of the multi-million dollar issues.

The manufacturing Industry should take a lesson from this costly "hands off engineering event". More on the multi-million dollar Chrysler Story:




INSTEAD OF WHINING ABOUT LOW WAGES IN CHINA: Joe, I want you to get this point across to everyone in this company. In this organization, it's a primary role of management to ensure that our work force has the necessary resources and expertise to always be one step ahead of any global manufacturing competitor
.



Unfortunately in this company we
still need to redefine what those resources need to be.




2008: Sometimes in manufacturing, it pays to take a look at past practices and see if we can learn from those that came before us. I remember making MIG welds on Massey Ferguson tractors in the nineteen sixties. The welds we made were in general superior quality with higher deposition rates than those typically made in 2014 at companies like Caterpillar and Deere.

2014: Looking back of course should also apply to the politics that daily govern our life. For example. While Congress has wasted the last six years disagreeing with the President on every subject he brings up, they do however have time to carry out interviews with over paid base ball players about their steroid use. Useless politicians, like useless managemers always has serious consequences. Today the interest on the US debt is measured in the trillions, the infrastructure that was a key factor for America's wealth is today turning to rust, the economy erodes daily, and thanks to those right wing Washington idiots and their tea part clowns, our global respect has never been so low.

2014: In many ways America today reminds me of the Roman empire during the early years of it's decline.
The Roman Senators (mostly lawyers) became rich from the payola paid to them by senate lobbyists. The self centered Roman Senators were simply not interested in maintaining the Roman empire or managing the annual fiscal requirements. In the time of slow Roman erosion, the Senators plan was a simple one. Keep the public focus off the economy and keep the focus on entertaining the citizens at the Coliseum. Today in America, politicians don't have a coliseum, (they do have the the NFL and NBL), instead they place there lies and fear campaigns based on deceit and public ignorance. The job description of many Washington politicians seems to be directed at keeping American minds of it' s environmental issues, it's crumbling infrastructure, the erosion of jobs and the middle class, high unemployment, too many violent crimes and of course the numerous health care and education issues.




While we should not live in the welding past, with processes that have hardly changed in decades, engineers and managers can learn from the past experiences, and implement the weld processs and manufacturing changes neceassry for at least a little weld optimization, with hopefully some manufacturing evolution.

 

 

 

 


"2010... Boys if you know anything about the second World War, it's ironic fact that with our high USA unemployment, you are today standing on a great new American ship made with steels and parts supplied from Japan, China, Russia and Germany.

"Now with one voice let's all sing God Bless America".



What happened to
the
Weld Management
.

Imagine the following in your weld shop:


[] Imagine daily weld shop management and engineering decisions that are made without the aid of weld sales advice.

[] Imagine management and engineers reading a book or taking a course on MIG Weld Process Control or
Best Weld Practices and actually taking an active roll in weld process ownership.

[] Imagine management and engineers who could look at any MIG wire feed control, the weld wire and the weld size and instantly tell you the cost of a weld.

[] Imagine management and engineers that are responsible for robots and these individuals truly understand the "people process control training requirements" necessary to attain optimum, consistent manual or robot MIG weld quality / productivity.

[] Imagine manufacturing plants that own robots that daily can achieve > 98% production efficiency potential and never attain more than 2% weld rework.

To meet the above requirements you may wish to check out my weld process control educational and training resources, after all weld process knowledge is the logical step to the establishment of Best Weld Practices and Weld Process Controls.



"MANAGEMENT & WELD ACCOUNTABILITY"


"Those bad welds, must be your fault".

.I GOT UPSET WHEN THE MANAGER SAID," ED THOSE GUYS ON THE SHOP FLOOR SCREWED UP AGAIN"?

During the last four decades, in thirteen different countries, as I visited hundreds of manufacturing plants, I frequently heard complaints from manufacturing - plant managers and engineers about the weld problems generated by
"those people on the shop floor". The message from this web site is consistent and will remain a fundamental one. If global weld management really wanted to know who was responsible for the root cause of their numerous, daily, manual and robot MIG and flux cored weld quality - and productivity issues, all they would have to do is look in the nearest mirror.

Global weld and mfg. management should be more like a ship's captain?

The majority of qualified ship's captains are supposed to be well acquainted with both the technical and "hands on" requirements of both running or repairing a ship. Every captain is aware that to have respect from the

hard working crew, the captain must show that they have full ownership, responsibility and accountability for the daily operations, the ship's equipment, the performance of the ship and of course for any repairs made on the ship.

In contrast to the ship's captain, we find that the majority of global major manufacturers of welded components, will hire managers and engineers who have the misguided believe that weld and related equipment ownership, and the responsibility for daily weld production and quality should be controlled by the less educated. lower paid individuals on the shop floor.




Many companies are not aware that if their employees had the required Weld Process Control Expertise, one robot would often do what many companies will purchase two robots to do.

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With common global robot MIG weld production efficiency typically in the 40% to 70% range and the average daily robot weld rework in the 20 to 100% range, thanks to the common lack of robot weld process controls and best robot weld practices, many mfg. plants are using 1.5 to 2 robots to do the work that could readily be achieved by one robot.

 

 

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Em developed the world's most effective MIG and Flux Cored, Manual - Robot, Weld Best Practices and Weld Process Control Training - Self Teaching Resources.


How sad a weld shop would be without thick skin and a sense of humor.




If asked for his opinion on MIG Spray Transfer versus pulsed MIG to weld carbon steels> > 5 mm), an unusualy bright fellow named Albert, a man who knew a lot about physics and the structure of the universe and other important stuff that did not pay his bills, might have made the following statement.

Maybe this would be Albert's Theory on "Regular MIG versus Pulsed welding".

"Em at your request, I studied the available regular MIG Constant Voltage Spray mode in contrast to the newer Pulsed MIG mode. It appears to me that with the coalescence and dynamics that are required to form a weld and to create consistent weld fusion in steel joints >5 mm), that the nearly constant weld joules attainable from the lower cost, Constant Voltage MIG equipment that provides the traditional Spray transfer mode, should of course always be superior to the Pulsed MIG. My answer is derived from the simple logic that that the alternating peak and much lower back ground current is necessary to form a pulsed MIG weld drop. Therefore from my humble perspective if a weld shop needs to attain consistent weld transfer with superior weld penetration on steels and alloy steel welds on parts > 5 mm, the weld shop should avoid the pulsed mode and use the older, Constant Voltage, MIG spray weld technology. You know Ed, the more I examine the weld processes, the more I regret wasting my time at school on math and physics and all that time I spent on dealing with that theory of relativity and
black hole bull shit.


.
A sad attempt at a welding joke by Em.



In many plants, when it comes to optimizing robot MIG welds,
TO SOME IT WOULD APPEAR THAT
M
ANGEMENT HAS RAISED THE WHITE FLAG



It's unfortunate in the many plants in which management and engineers shy away from the important processes that are important to their profits, that it's the shop workers that daily suffer the manual and robot weld consequences: In these plants the blue collar guys;


[a] rarely receive parts to be welded that have dimensions in accordance with the design and manufacturing tolerances,

[b] rarely will be provided with the optimum size and type of the weld consumables selected,

[c] rarely will be provided with optimum weld process and weld procedures,

[d] rarely will be guided by management - engineered driven best weld practices - process controls,

[e] rarely will be aware of the weld costs or real world weld production efficiency potential of their manual welders or robots,

[f] rarely will receive the required robot or manual "weld best practices - process control" training necessary to optimize the equipment, the process and the quality.


Yet these long suffering, mismanaged shop floor personnel will daily be held accountable for the plant's weld quality and productivity issues.


THE INFLUENCE OF MANAGEMENT WHO LACK THE ABILITY TO CHANGE
AND EVOLVE "A PLAY AROUND INDUSTRY".


Would a professional foot ball coach let the players play around in the middle of the field during a game? Would a machine shop manager smile as as he watched his machinist play round with their machine controls. Yet few weld shop or mfg. managers seem concerned while their weld personnel "play around" with their weld equipment controls..

This will rarely happen. A message from a frustrated corporate manager to his manufacturing manager:

"Joe, after watching your robot personnel play around with those weld controls, and reviewing the extensive robot weld productivity and quality issues in this plant, I can only come to one conclusion, it's time for us to change our approach to the robots and automated weld manufacturing.

Lets face it Joe, the people on the shop floor "are not the root cause of our robot weld issues". The bottom line for this company is our managers and engineers have to recognize that they have the full responsibility and accountability for the daily weld quality and productivity produced in the plants. Joe this organization needs to understand weld process controls and how to establish best robot / manual welding practices. Joe our managers and engineers should have or attain the ability to recognize the weld process expertise thats both necessary for themselves and for our shop floor employees that are making the day to day weld decisions.



Where does the BUCK STOP IN YOUR PLANT?




FOR MORE THAN TWO DECADES IN THE WELDING INDUSTRY, ONE THING THAT WAS DIFFICULT TO FIND, WAS MANAGERS, SUPERVISORS & ENGINEERS WHO WOULD ACCEPT FULL OWNERSHIP AND RESONSIBILITY FOR THEIR WELD EQUIPMENT - PROCESSES AND CONSUMABLES.

It could be a generation thing, or just the way the industry is evolving, but have you noticed how difficult it is to find either a plant manager or federal politician who will take ownership and full responsibility for their daily actions and who actually knows where the buck should stop.


Since the first welds were made in a manufacturing environment, it's always been logical that the responsible managers and engineers should understand the primary weld and related equipment they have managed or purchased, and they should have the ability to recognize the common root causes of the daily weld issues that impact their weld quality - productivity. It's also logical that all the responsible engineers have the ability to provide the shop floor employees with the necessary weld process control and best practices training resources.

.

How common do you think this is
in the global MIG weld industry?




Come on you Chicklets Miglets, we have to
follow him, after all, he is a weld "salesman".


MORE ON THE WELD MANAGEMENT & THE - ENGINEERING DISEASE I CALL, "SALES RELIANCE":

For over five decades, in the majority of global weld shops that utilize the MIG and Flux Cored weld process, you would often find an umbilical cord attached from the weld shop supervisor, the manufacturing manager or engineer to some "weld sales person".

As a former training manager for three of the world's largest weld product suppliers, I have trained over a 1000 weld sales personnel. I would estimate that less than ten percent of the sales reps I worked with had the correct qualifications to provide weld process and application advice to any weld shop. If you are a supplier and have employed a qualified individual, hold on to that rare person. The irony in our industry however is that the majority in the global weld industry when dealing with weld issues will look for advice from a sales industry in which approx. 90% of the sales persons are not qualified to give that advice.

Many of those managers, who in the morning will fight their weld production - quality fires, will then in the afternoon take refuge in their offices while they oversee often unecessary meetings. After the meetings the rest of the day will be spent searching for any new crutch that they can direct at the latest weld shop issues.

The management crutch is often an expensive one. The crutch may mean the purchase and trial of unnecessary three part. MIG gas mixes or costly, ineffective, metal cored or flux cored wires. Of course the largest weld cost waste will typically be when the management orders those costly electronic Inverters or pulsed MIG weld equipment, both of which are typically loaded with useless bells and whistles.

While many managers in large companies do not think twice about the purchase of those $12,000 pulsed MIG power sources for their steel weld applications, few of these managers have considered the cost effective feature benefits of providing low cost weld process control training to a work force that for decades has "played with the MIG weld controls".


THE BOTTOM LINE: With the right weld process control training, in a few hours, any worker would have the ability to be able to take a low cost, $2000 - $3000, traditional, CV "none pulsed" MIG power source, combined with a simple two component gas mix and a low cost MIG wire, and make the low cost MIG equipment perform as well as a $12,000 power source.

 

 



THE MAJORITY OF FABRICATION & MFG. PLANTS HAVE DAILY
PAYED A PRICE FOR THEIR SLOW WELD PROCESS EVOLUTION:





In the USA, many mfg. plants involved with both robot and manual welds were closed and the production was moved to Mexico or China. Apart from the obvious lower labor costs of these countries, another reason rarely discussed was many of the plant closures were also influenced by their managers and engineers inability to daily, consistently produce the highest possible weld quality at the lowest possible weld costs?



.

How about our organization? Do you know where the buck stops when it relates to those weld issues. Does the buck forage on your weld shop floor, or would you find him looking confused in your front office?

 



 

GLOBAL TRAINING PROGRAMS AND MILLIONS OF DOLLARS WASTED: While the major automotive plants typically spend over a 120 million dollars annually on training, yet in many plants such as Ford, GM and Chrysler, (plus tier suppliers), the typical MIG welder or robot weld technician does not know how to set and optimize a simple two control conventional MIG power source and wire feed. For example while i was at one prime Ford frame plant, with the engineers looking over their shoulders, the manual MIG repair welders welding on truck frames with the contact tip bore three times the size it was supposed to be. The oversized bores lower the weld current and created arc instability resulting in welds that could not be defined as welds. A good contact tip would have cost about 90 cents. A good contact tip and a welder who had received affective process training may have maintained the structural integrity of the truck frame.

All auto - truck corporate management need to take a closer look at the quality and effectiveness of it's welder and robot technician training programs. The evaluation would reveal that the weld programs typically lack best practices - process controls. It's also interesting that with the big three, the managers, supervisors and engineers who are supposed to be responsible for the welded components will rarely be participants in the programs. if I was an ivory tower big three executive, i would take more than a passing moment to reflect on the relationship between the quality and effectiveness of the training programs provided,the lack of management and engineering process ownership and the liability consequence, the warranty costs, the product recall costs, the weld rework costs, poor productivity costs and unnecessary capital investment costs from an organization that lacks the ability to implement best weld practices and process controls.





How much bang does your company
get from from it's training dollars?






MANAGEMENT WHO ARE NOT AWARE OF EITHER THE ROBOT PROGRAM OR WELD PROCESS CONTROL TECHNICAL REQUIREMENTS, WILL RARELY GIVE CONSIDERATION TO THE LEARNING CAPACITY OF THOSE THEY SEND TO TRAINING PROGRAMS:

Every time new robots are ordered, the plant management will typically select personnel to send them to a "robot programming school" When I was the USA. Robot Weld Training Manager with ABB Robotics, it was notable that when I presented the Robot Weld Process Control and Best Practice Training programs, the Big Three plant management would often send employees that could barely read. Training for programing a robot is one thing, what about the training required to implement weld process controls and best weld practices. In the last two decades, few manufacturing or plant mangers involved in arc welding robots, gave consideration about sending personnel for robot "weld process control and best weld practices training".




If you think weld process control expertise is not important,
why not try this MIG Weld Process Control Test:

If you have an interest in establishing effective best practices and process controls, you may wish to provide your robot employees with this fundamental MIG and Robot Weld Process Control weld test. At the test completion ask yourself, is this the type of process control data our employees require to attain consistent, optimum manual / robot weld quality and productivity?

Ed spent more than 25 years developing the unique but very simple "Weld Clock Process Control" method. This is world's most effective MIG / flux cored weld process control training program. To ask Ed about this unique yet simple training program, contact Ed at
E-mail. ecraig@weldreality.com




"WELD SAFETY NEWS FLASH"

 

Important Safety Weld Concerns for 2007.

Click here for the following weld safety issues.

[a] OSHA held hearings on it's proposal to reduce the PEL for hexavalent chromium from 52 micrograms per cubic meter to "1" microgram per cubic meter as an 8 hour time weighted average. See the latest ruling from OSHA.

Is it MIG, flux cored or SMAW that create the most stainless fumes concern?

[b] Welding on special stainless steels causes occupational asthma.

[c] Manganese welding fume law suit and issues with other alloys and weld fumes.

[d] Radioactivity and tungsten TIG electrodes.

[e] Galvanized Fumes?

[f] Carpal tunnel and MIG guns.



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WHEN YOU HAVE "HANDS OFF" WELD MANAGEMENT, YOU OFTEN LY END UP WITH AN ORGANIZATION IN WHICH THE COMPLETELY UNQUALIFIED, PURCHASING MANAGER BECOMES INVOLVED IN THE WELD EQUIPMENT AND WELD CONSUMABLE PURCHASE DECISIONS:



Note: For those purchasing managers looking for low cost welding shields,
we ship our disposable $2 weld helmets direct from China





After spending thousands on repairs of his Chrysler Minivan, my brother went for a more reliable vehicle.


More at page 3



All programs at www.weldreality.com

 

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