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Summary and
Outline of Modules
Click on ICON |
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Gas Saver System;
a Key Element of Our WA Technology
Lean Welding Manufacturing Tools
"Optimizing Shielding Gas Use and Eliminating
Waste"
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A SHORTER PROGRAM WITH LESS
THEORY
"JUST THE FACTS"
Designed for Welders and Welding Foreman
"Setting Gas Flow Rates and Reducing
Waste"
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| An important tenet in Lean Manufacturing is
understanding the savings possibilities. One statement made is
"Most of the Waste in Manufacturing is Invisible."
That sure fits "Shielding Gas Waste, in More ways than One!"
Also, did you know if shielding gas is leaking out of a hose or fitting air
and moisture are leaking in! Sounds strange--it's true. The
reason is defined in our program.
If your into "Lean" than you know
"sustainability"
is the key to maintain your progress. We discuss simply
ways to have your workforce maintain the waste reduction and quality
improvement you'll achieve with our approach. |
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The Gas Saver System
can provide significant savings in
Shielding Gas Waste due to excess surge at the weld start.
That surge not only wastes a significant amount of shielding gas but also
deceases the quality of weld starts. That can mean rework, grinding
and excess spatter that may require post weld cleaning--all wasted effort.
Just ask your lead welder. They can hear the gas surge. Some will tell you,
as they have us, "The shielding gas surge blows
away the arc at the start." That is not really what happens
but the end result is similar!
You can save even more with our
"Lean Welding Manufacturing
Tools." How? :
Assign your lead
welder, welding foreman or welding supervisor the task of
measuring gas flow. Have them review the information provided in our
Lean Welding Manufacturing Tools.
That will define the maximum shielding gas flow rates they should use.
It will show them why excess shielding gas pulls air into the shielding gas
stream making shielding quality worse not better. Have them measure flow on all
welding machines and discuss desirable flow rates with all welding
related employees.
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In addition to excess gas flow surge at the
weld start, setting the proper gas flow rate
is very important. Unfortunately welders often follow the adage,
" If a little is good more
must be better." Our training material outlines the maximum
flow that should be used before your pulling air into the shielding gas stream. It
defines how much draft or wind can be tolerated in MIG welding and why
increasing flow beyond defined levels makes shielding worse. |
That person(s) will learn how to check for
gas leaks in the delivery system and at the welding torch. They can plot
flow rates on each machine once per month and detect possible leaks.
They will learn how a 0.035 "wire size" leak in a 50 psi gas pipeline or hose can
cost over $14,000/year. Fixing one leak of that size will
payback the cost of the
program in 2 weeks !!
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With a little information from purchasing they
can also plot the total shop use of shielding gas each month and divide it by the
pounds of wire used. Our Lean Welding
Manufacturing Tools show a simple way to develop and use a 3
to 6 month rolling average of this ratio to raise a red flag when values
increase. It also provides benchmark data to compare your rates
with industry standards. |
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They can communicate their findings to all
those involved in welding by posting a simple graph of the manufacturing
bulletin board that is easy to understand.
Maintaining a focus on gas usage will help reinforce the waste and poor weld
performance that will occur from excessive gas flow rates set by a welder or
occurring at the weld start. |
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Want details of what is included in
Lean Welding Manufacturing Tools?
Just Click
on the One You Want
"Optimizing Shielding Gas Use and Eliminating
Waste"
or the condensed version
"Setting Gas Flow Rates and Reducing
Waste"
or a basic "Self Study" Program
"Understanding and Setting
MIG Gas Flow Rates" |
Purchase
Lean Welding Manufacturing Tools? |
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Background in Lean Manufacturing
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