weld consulting.htm

 


IT'S ALWAYS A GOOD TIME FOR MANAGEMENT
TO GET CONTROL OF THE WELD SHOP,
MICRO MANAGE WELD
COSTS
AND
OPTIMIZE THE WELD
QUALITY & PRODUCTIVITY.


Contact Ed Craig at 828 658 3574


WHY SHOULD A COMPANY CONSIDER BRINING ED TO THEIR FACILITY?
It's hard for many individuals to implement welding changes unless that person can actually demonstrate that the changes are beneficial and cost effective. Its may be difficult for your weld decision maker to convince weld individuals that the weld practices they have been doing for decades may not have been optimum

CATALYST FOR WELD CHANGE. Sometimes it's beneficial to bring in an outsider like myself to be the catalyst for the necessary weld shop changes. With a short term contract OF TYPICALLY 3 TO FIVE DAYS, I have the unique skills necessary to resolve your welding issues, establish Best Weld Practices or Process Controls or completely reorganize your welding department to be more cost efficient and produce superior, consistent weld quality.

PROCESS EXPERTISE. In contrast to many traditional managers, I have the practical weld skills and extraordinary weld process control expertise necessary to instantly set optimum welds on any applications from a high speed, production robot MIG welds to all position MIG, flux cored or TIG pipe welds. I also have extensive expertise in establishing effective weld process controls for automated GTAW pipe and cladd welds or for those micro GTAW / plasma welds as used in the electronic, medical industries.

WELD CREDIBILITY is an important management trait for any welding shop undergoing change. My hands on approach and weld process expertise on most processes quickly provides that credibility. My ability to cut through weld shop myths and the sales influenced weld damage
is again important for the implementation of the most cost effective ways to weld.

SHOP CULTURE. It takes years to develop a weld shop culture, however in a matter of days, I can get your manual or robot welding department out of it's bad habits to a level where it attains it's highest weld production and quality potential.

 

 

Should the welding quality and productivity of your manufacturing company rely on the expertise of a salesman?


Of course you may ask why bring me to your shop when you can get "free advice" from the major weld equipment manufacturers.

For decades the welding industry has relied on the companies that make welding equipment and consumables to provide practical MIG welding process and application advice. Lincoln Miller, Hobart and ESAB have had fifty years to educate MIG users on how to control a process that has two simple weld controls. Fifty years later and the majority of global weld personnel still play around with MIG and flux cored weld controls.

 

The universal lack of GMAW (MIG-MAG) weld process expertise that today prevails throughout the global welding industry has to be an indication of the quality of the "free weld advice" provided by salesmen.

 

 


A LOW COST, FAST SOLUTION TO YOUR ROBOT AND MANUAL WELD ISSUES.

Ed whas resolved over 200 global companies weld issues on the phone.

If you are having robot issues that affect your weld quality productivity or down time, or if you want the best method and procedure for those manual welds, call Ed at 828 658 3574, (eastern standard time USA). The one day weld resolution fee is $375 paid with Visa or MC.

Ed will visit you facilty and provide hands on , instant solutions to all your robot / manual weld issues and a unique simple process control training program. In one to three days you will experience dramatic improvements in your MIG and flux cored weld quality and productivity. Cost $1275 daily plus exp.

 


ROBOT MANUFACTURERS & MIG EXPERTISE:

If Lincoln, ESAB Miller and Hobart after four decades of manufacturing MIG equipment have not been able to educate welding end users on how to control the MIG process, then how "weld qualified" do you believe the Japanese, Swedish, Austrian, German robot manufacturers are?

MOST ROBOT APPLICATIONS ARE ON SIMPLE, CARBON STEEL GAUGE APPLICATIONS <5mm, HOWEVER THE DELUGE OF DAILY WELDING PROBLEMS ON THESE APPLICATIONS COST THE MANUFACTURING INDUSTRY DEARLY.

WHY BOTHER CALIBRATING THE ROBOT. 1987-2007: For two decades many robot manufactures and intergrators have not calibrated the wire feed rate, weld current or weld voltage shown on the robot pendant with the actual welding parameters.

When I first went to work as a senior weld engineer for one of the largest and most respectable robot manufactures, I was amazed to find their weld robots would be sent to customers without weld parameter calibration between the robot control, interface and power source. Put a wire feed speed of 600 in./min and 30 volts into the robot weld program and the customer may have in reality received a weld with 400 in./min and 25 volts from the power source. I found out the calibation issue was a univerasl robot problem and in 2007 its still a common issue.


With many robot companies and intergrators, the weld application and weld process are typically secondary to the robot profits and related equipment sales. At an automotive company I visited in Canada, the Motorman robots used Hobart power sources. The welding current on the power source meter indicated 250 amps, the current programmed on the robot pendant was 390 amps. How can any company establish effective welding procedures with this nonsense? How can anyone provide effective process training for robot personnel? How can a company comply with ISO requirements if the weld data you work with is meaningless?

Next time you order a robot remember "robot companies have a prime concern their annual volume of robot sales, few companies are concerned about your robot weld process issues. To get the correct tobot calibration data that should be on the robot purchase contract, I highly recommend my Robot MIG process Control training program.

 

Because in a firm manner I will work with your weld team to cut through the weld shop issues, the weld salesmanship influence, and the weld shop myths. I will provide the most practical welding solutions for the lowest possible costs. From welding pipe lines to robot welding Cadilacs,
I first produces the weldS you want to see. I will then train your workers to produce the same optimum welds in a consistent manner.

At a Textron a Wisconsin company that makes heavy construction equipment, while maintaining the same labor force, Ed led the welding team and doubled the weld production within 12 months. This was achieved with no increase in labor costs and an increase in annual capital weld expenditures of only 10%.

At Dana an automotive company that makes frames cross members in less than two weeks, with process and robot modifications I increased the daily weld productivity by 50% and the weld quality reject rate was reduced from 40% to less than 3 %.




Visit all the MIG and flux cored Best Weld Practices
and Weld Process Control Programs at this Site.


E-Mail Ed. ecraig@weldreality.com.

For phone or inhouse weld resolutions call Ed at 828 658 3574.

Visit Ed's Robot and Manual Process Control Training resources.

 

 

Eds Resume

 

WHEN YOU ARE READY FOR WELD PROCESS CONTROL,
GIVE ED A CALL AT
828 658 3574.

 

 

 


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Email Ed Craig at ecraig@weldreality.com
If urgent call Ed at -
843 298 2054

 
 
 
 
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