Lean Welding Manufacturing-Shielding
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Lean Welding Manufacturing Tools
Managing Shielding Gas Use
of Lean Manufacturing 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
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.
Note: As a Senior
Manager for a welding equipment manufacturer, participated in a
1 million + dollar improvement program with DeWolff Boberg and Associates,
Management Consultants. They worked closely with the production team
and hourly workforce and saved well over the expenditure. Each of the
work teams would report results summaries to the senior management team.
The analytical approach learned and used by many of the hourly workforce was
See Background in Lean Techniques
You can save significant $'s in wasted
shielding gas and improve weld quality with our,
"Lean Welding Manufacturing
your lead welder, welding foreman or welding supervisor the task of
measuring gas flow (an inexpensive tool is all that is needed.) Have them review the information provided in our
Lean Welding Manufacturing Tools, Self Study Course.
That will define the maximum shielding gas flow rates they should use.
It will show them why excess shielding gas flow rate 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
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 air is pulled 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 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 a week !!
With a little information from
purchasing they can plot the total shop purchase of shielding gas each month and divide it by the
pounds of wire bought. 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.
They can communicate their findings to all
those involved in welding by posting a simple
Graphical Chart (Included with the Course) on a
Bulletin Board reminding all of why excess gas flow creates problems.
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.
It includes a simple method to
use to calculate the actual leak rate in pipelines. After conducting
the 1st test it can be repeated on an ongoing basis in a mater of minutes
with just the use of a watch!
Want details of what is included in
Lean Welding Manufacturing Tools?
"Optimizing Shielding Gas Use and Eliminating
Waste" WAT LWM-SG
or a basic "Self Study" Program for Welders
"Understanding and Setting
MIG Gas Flow Rates" WAT-UFG
Lean Welding Manufacturing Tools
Background in Lean Manufacturing