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Home page for weldreality.com. ©.xxxx

Welcome to the world's largest web site on MIG and Flux Cored, Weld Process Controls & Best Weld Practices

The site provides all the programs and information that is necessary to select the lowest cost MIG weld equipment and weld consumables, and consistently attain the highest possible manual - robot, MIG & Flux Cored weld quality and productivity.


Please refresh this page as it's updated frequently.




This web site was first established in 1997 by Ed Craig.
Contact Ed. ecraig@weldreality.com. Pho. 828 337 2695.

 


To get to the root cause of weld issues, needs some weld reality.




The MIG, (GMAW) and Gas Shielded Flux Cored, (FCAW), weld processes, have for deacades accounted for more than 80% of the global welds that are produced daily.

It's unfortunate that the majority of manual and robot weld decision makers throughout the weld industry, have not focused on the extensive weld quality improvements and weld cost reduction benefits, that can be attained from MIG and Flux Cored, Weld Best Practices and Weld Process Control Expertise


Most experienced weld decision makers, will be aware that the best possible weld quality - productivity, with the lowest cost welds, can not be attained from personnel that have to play around with their MIG or Flux Cored weld controls
.
In most global weld shops, it's not uncommon to find the following.

[] EXPERIENCED MANUAL WELD PERSONNEL THAT WILL PLAY AROUND WITH WELD CONTROLS THAT HAVE HARDLY CHANGED IN 50 YEARS.

[] Key weld decision makers who are not familiar with the manual or robot, MIG and flux cored requirements for Weld Process Controls
and Best Weld Practices.

[] WELD MANAGERS AND SUPERVISORS WHO OFTEN FOCUS ON THEIR WELD CONSUMABLE COSTS, AND YET ARE NOT AWARE OF THE WELD DEPOSITION RATE POTENTIAL OF THEIR COMMON WELDS, AND THE EXPERTISE, CONTROLS & PRACTICES NECESSARY TO PRODUCE THE LOWEST WELD COSTS.

Note: In the hundreds of companies that I visited in 13 countries, I never talked to one weld decision maker who knew the real weld costs of the conmmon welds they daily produced..

[] TOO MANY GLOBAL WELD DECISION MAKERS, WHEN PURCHASING MIG WELD EQUIP AND WELD CONSUMABLES, WILL RELY ON BIASED, INEXPERIENCED, WELD SALES ADVICE.


[] In most auto - truck plants, you will find managers and engineers that will order new robots, while the robots in their plants are greatly underutilized. The poor robot utilization is typically due to;
[a] lack of awareness of the real robot weld productity potential,
[b] inconsistent daily weld productivity from lack of weld process controls and best weld practice expertise,
[c] unnecessary robot down time each shift.
[d] poor engineering - mfg practices with the parts produced.
[e] poor design with the robot parts, the fixtures or the robot cells.

COMMON GLOBAL, WELD SHOP ISSUES.

Lets face it, if you have worked in more than one weld department that utilized the MIG or Flux Cored process, you will have likely experienced the common weld shop reliance and consequences from accepting weld sales advice. Also you may have had to daily listen to confused weld discussions that had more usually were based more on myths than reality. As you walked through the weld shop, you may have wondered, why the wide variety and lack of uniformity in with the MIG equipment, weld guns, weld wires and gas mixes?. Or perhaps you simply wondered why no one ever discussed how to control the real costs associated with the welds, or why there was no evidence of the implementation of cost effective, best weld practices.



In the numerous global weld shops in which the front office personnel do not take ownership and responsisbilty for the MIG equipment and processes on the weld shop floor, you will find weld personnel that play around with their weld controls, and the management usually ensures that their welders never run out of the never ending grinding discs that are always needed when weld processes are not optimized..

WELD COST CONFUSION ENABLES WELD COST OPPORTUNITIES?

In most weld shops, the management focus on weld costs will often be on the costs of the welding consumables such as wires, gas mixes and grinding wheels. In North America, weld consumables typically account for approx. 15 to 18% of the actual weld costs. If management is not focussed or knowledgable about the requirements of weld process optimization, it's impossible for them to control their weld costs, and therefore it's impossible for them to optimize the companies weld profits.

Many of you that are involved with MIG and Flux Cored weld costs, will be aware of the complexity that can surround this important topic. You will be pleased to know that my training materials, simplify this subject.

ANY TECH INDUSTRY IN WHICH THE MAJORITY OF MANAGERS AND ENGINEERS RELY ON SALESMAN FOR GUIDANCE, WILL BE AN INDUSTRY SATURATED WITH USELESS BELLS & WHISTLES, AN INDUSTRY WITH EXTENSIVE COST REPERCUSSIONS.

When MIG or Flux Cored manual or robot weld issues occur, many weld managers, engineers, supervisors or technicians will not think twice about getting 'weld advice from the local weld sales rep. The rep is often an individual who has never run a weld shop, a person who is more likely to have a degree in History, English or the Arts. Lets face it, if a weld shop wants to attain maximum weld profits, that shop should be run by individuals who understand the requirements of weld process controls and best weld practices and the importance of weld process ownership.

ANY MANAGER WORTH A PINCH OF SALT, WOULD ASK THIS QUESTION.

Many in the global weld industry could ask this simple question. 'Why are so many weld issues daily generated with the MIG - Flux Cored processes, two weld weld wire processes, that have two simple controls that have not changed in decades? The answer is a simple one. The global weld industry and weld education facilities, have simply never focussed or understood, the weld Process Controls - Best Weld Practice requirements for the MIG and Flux Cored process.




Why play around with MIG controls
when you can use;


Skills are only a small part of weld optimization.



To create substantial weld cost savings. requires change, and that change will be driven from Weld Process Control Expertise


Perhaps you are a manager, engineer, supervisor, technician, or any weld person that believes your career weld prospects will improve with Weld Process Control knowledge? Or perhaps you are a manufacturing engineer or manager that wants to optimize your companies manual or robot, MIG - FCA weld quality and productivity. If so please take a moment to review my MIG and - Flux Cord Weld Process Controls and Best Weld Practice Resources.






What you will find at this weldreality.com, home page.

[] You may want to know the reasons the global weld industry annually wastes hundreds of millions of dollars on the purchase of useless, three part gas mixes, costly cored wires, and costly pulsed MIG equipment that's mostly loaded with useless, electronic bells and whistles.

[] I have trained over 5000 personnel to optimize MIG - flux cored welds. Myself or my trainers, could take an individual who has never welded and in less than 60 hrs, have them pass any code weld test requirements. With this in mind you cannot pick up an engineering magazine these days and find some weld shop manager complaining about their concerns for finding skilled MIG or Flux Cored welders.
Note: TIG (GTAW) welder training is simplified if TIP TIG is utilized.

[] If the weld decision is not optimizing a process they simply cannot be in control of their weld costs. In the majority of weld shops, you may not want to go looking for anyone in weld supervision or management that could in two minutes work out the real cost of their most common MIG or flux cored welds?

[] Why do most of the companies who employ QA, weld inspection resources, have personnel who are daily focussed on finding weld defects at the weld completion, when the reality is, with a few hours with the training resources at this site, those same personnel could quickly be be trained to provide the expertise necessary to prevent those costly weld defects.

[] It's reasonable for anyone involved in engineering department to ask. "Should a designer call themselves a professional engineer, if the designer of welded parts does not understand the fundamental weld process requirements, the weld benefits and weld limitations of the weld processes that they have selected to weld their parts"?

[] In most global manufacturing companies that utilize MIG welding robots, especially in the auto - truck industry, it's difficult to find management, engineers, supervisors or technicians who actually have the MIG weld process control expertise, and the best weld practice knowledge necessary to daily attain consistent, optimum weld quality, with maximum weld productivity.


[] The sad, apathetic, engineering - weld issues I saw at the construction of the Bejing Olympic Stadium, happens every day on large construction projects around the globe.

[] Take a moment with a new welding process called TIP TIG. This is a process which I brought to North America and Australia. This process is is the best possible process for all position, code welds, and all alloy applications.





Common weld issues that occur in global weld shops:

The following are a few of the reasons why it’s important that every one involved with weld decisions, receive the missing link in most weld shops, MIG - Flux Cored Weld Process Controls and Best Weld Practices Training.

[] When given a new part to weld, most experienced weld personnel are not sure of the optimum data, consumables or weld transfer modes, and instead play around with their weld controls?

[] In too many weld shops, no matter what application is being welded, many of the welders will set their MIG or Flux Cored weld controls at one scratch mark on the wire feed control and power source.

[] With optimum quality welds, it's the weld deposition rates that drive the weld costs. Yet in most weld shops it's difficult to find any weld personnel that are aware of the deposition rates they are attaining on their common welds, or the weld deposition rate potentials with the weld processes, consumables they daily utilize.

[] If you were to ask some of your MIG or flux cored weld personnel to provide more weld heat to improve the weld fusion, some will turn up the wire feed speed, while others will turn up the weld voltage.

[] If you were to ask the manager, supervisor or weld technician responsible for the MIG or flux cored weld quality and productivity, to let you know the approx. cost of the common 1/4 (6mm) horizontal fillet weld that is 3 feet (1 meter) in length, you may find that person wants to change the subject.

[] A large fab shop could easily spend $150,000 annualy on grinding discs and over $500,000 annualy with grinding and weld cleanup labor costs for it's MIG or flux cored welds. It's therefore logical that any manager would want to reduce these costs. However in this company, as with many companies, the welders are attached to their grinders with an umbilical cord. The welders are creating unnecessary spatter and weld cleaning from welds that were set with erratic, globular transfer. The process solution is simple and it costs about $400.

[] You just started in this weld shop and you ask the weld supervisor to justify why he wants to purchase a costly pulsed MIG power source, metal cored wires, or a three part gas mix. Listen closely to the answers as you will hear the words of a salesman. 

[] Any manager or supervisor, would want to know how much their weld personnel understand the MIG process. All it takes is one fundamental MIG weld question. One of the world's most common MIG wires are the 0.035 - 0.045 (1 - 1.2mm), E70S-3- 6 wires.

Question: You ask the experienced MIG weld personnel. Using an argon 10 - 20% CO2 gas mix. What is the spray transfer start point weld voltage and wire feed rate for either that 0.035 - 0.045 wire?

It's easy to dramatically reduce MIG - Flux Cored weld costs, reduce weld rework and minimize any companies liability consequences from a future weld failure, that is, once the management and engineers are aware that they should provide weld Process Control and Best Weld Practices Training for those on the weld shop floor and those in the front office.







I provide customized MIG - Flux Cored
Weld Process Controls and Best Weld Practice
Training, in Asheville. NC.



Wikipedia Photo by Ken Thomas Rainy.


The Blue Ridge Mountains on Asheville's door step, North Carolina
Send your mgrs, eng, supervisor, trainers or technicians .

In the highly competitive global weld industry, weld business survival will be achieved by those companies that can consistently produce the required weld quality, with the highest productivity at the lowest possible weld costs.

Extensive weld cost savings are easily produced in weld departments in which weld personnel play around with their 60 year old, two controls, MIG and flux cored weld processes.

Extensive weld cost savings are easily produced in weld departments in which weld processes and transfer modes are poorly understood, and rarely optimized

Extensive weld cost savings are easily created when weld rework is the norm or the weld deposition rate potential is rarely attained.

Extensive weld cost savings are easily produced in weld departments in which the weld decision makers have relied on weld sales reps for weld advice.

Extensive weld cost savings are easily generated in companies that have a poor understanding of weld costs.

You may wish to s
end your weld decision makers or trainers to my location at Asheville, North Carolina. With my two day customized programs. I will send you back experts in either manual, or robot, MIG - Flux Cored Weld Process Controls and Best Weld Practices.

For info. Ed Craig. 828 337 2695. E-Mail ecraig@weldreality.com.

E-Mail. Ed I wanted to send update about that E-Town, DANA plant
that you visited a few years ago. As you know on your first visit, our robot MIG welding lines were producing less than 40 Ford F-150 truck frames per-hour, and over 90% of the frames required extensive weld rework.

Thanks to your Robot Weld Process Controls - Best Practices Training program, and your process and consumable recommendations, the robot weld results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily attain our average goal of one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.

Many thanks! Ryan Good.
A grateful engineer, and a grateful DANA Corporation.

Note The DANA corporation is a tier one supplier and a world leader in the supply of drive line products such as frames, axles, drive shafts, and transmissions for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.

E-Mail. Dear Ed, I want to let you know that by using your MIG weld process control - best practice methods in one of our plants, we have now dramatically improved our MIG weld quality - productivity and reduced our labor - filler metal costs by approx. 45%. We intend to utilize your training program in all our plants.
Lawrence Bower CWI/CWE.
Chief Welding Engineer.
NCI Group. Houston TX.

Ed's MIG Weld Process Controls & Best Practice Test.

How much do you know about MIG - FCAW Process Controls - Best Weld Practice. The bottom line is Universities, Colleges & Training Facilities, don't provide the weld industry with the process resources they need.


Ed's Flux Cored Weld Process Control & Best Weld Practice Test.

 

 




What NEW?.

WHILE THE USE OF ALUMIUM PROVIDES SOLUTIONS FOR THE AUTO - TRUCK INDUSTRY, IN THAT IT ALLOWS VEHICAL WEIGHT REDUCTION, THE PROLIFIC USE NOW PROMOTED BY FORD SENIOR MANAGEMENT FOR THEIR F150 TRUCKS, COULD END UP AS AN ULCER EPIDEMIC FOR MFG PERSONNEL.

MIG welding is a prime manufacturing processes in vehical production, yet the apathetic weld reality is, that during the last three decades, (since the intro of robots) the majority of auto - truck companies and their tier suppliers, have employed managers and engineers that lacked the ability to control and optimize this simple two control process when robot welding easy to weld carbon steels.

As with most other major companies that utilize large numbers of robots, Ford is a company saturated with engineers and - designers that are not aware of what robot weld process control expertise is, or what they could attain through the implementation of robot best weld practices. The sad reality is apart from the millions of dollars lost daily, in poor robot weld productivity, rejects and rework, the human price paid for robot weld process ignorance in the global auto - truck industry is, loss of engineering pride and job satisfaction, loss of sleep, and of course an increase in ulcers,

Info on the Alum Ford welds on home pages, 1 - 2.

My PULSED MIG annual update:

As some of you are aware, over the last twenty five years, in my books, articles and in the pulsed MIG data and pulsed MIG equipment on this website, I have reviewed the MIG weld application potential, or MIG equipment cost justification for the purchase of the pulsed MIG process.

Pulsed MIG equipment can typically cost 100 to 300% more than regular CV, MIG equipment. During In this time period, my conclusions were. I found pulsed MIG provided real world weld benefits on the following, 'very limited weld - clad applications";

[1] Pulsed MIG benefits aluminum parts less than 5 mm,
[2] Pulsed MIG benefits specific alloy clad applications,
[3] Pulsed MIG benefits specific "automated" pipe applications,
[4] Pulsed MIG benefits specific alloy applications > 4 mm, in which many welds may be located in a small or restricted areas, and where spray transfer if used, would put in too much weld heat .

Pulsed MIG is simply one of a few practical MIG weld transfer modes. For those of you not aware. I developed a pulsed MIG clad weld patent that has had a dramatic influence on reducing boiler, water wall, MIG weld clad costs for the global power industry. This patent also dramatically improved the traditional clad weld quality and dramatically extended the life of the water wall tubes. I have worked with the Pulsed MIG process, for approx. three decades. However my weld reality in 2014 is this. Apart from the above 4 very narrow weld - clad applications, when welding the majority of the common, steels and alloy steels "weld applications", the only persons that that will typically profit from the purchase of the costly, less durable, pulsed MIG equipment, will be the weld distributors who sells these units, and of course, the weld equipment manufacturer that makes the costly pulsed MIG units.


If someone in your organization believes that in contrast to the much lower cost, much more durable CV MIG equipment, that they can justify paying 100 to 300% more for pulsed MIG equipment, I believe they have been influenced by a salesman, and the reality is the purchase of the pulsed MIG equipment for steel or low alloy steel welds, is usually an indication that the weld shop management lacks the MIG weld process control expertise necessary to optimize the regular, CV welds.



Pulsed MIG information at this site.

Pulsed MIG Weld Process Information

MIG & Pulsed MIG Equipment Evaluation

Pulsed MIG Clad Information.

All programs at this site.

 

 

When the blind have to lead the blind, you know there will be issues.

Anyone in the weld industry that has a logical mind, would find it makes little sense to ask the weld personnel that "play around" with their MIG or flux cored weld controls, to evaluate new cored wires, three part gas mixes, or that sophisticated pulsed MIG equipment.

When looking at achieving extensive weld costs reduction, managers will find it's highly cost effective if they would first recognize their companies lack of MIG or Flux Cored weld process control expertise. Then spend a few dollars to educate all those involved in weld decisions.




For the most comprehensive data on why you may not want to
purchase those costly pulsed MIG units, click here.




There are extensive weld cost reduction opportunities for managers - engineers, supervisors and technicians, who will take a few hours to learn manual and robot, MIG - Flux Cored, Weld Process Controls, and Best Weld Practices.


Dec. 2013: Ford Motor company senior management and engineers announced they have decided to use large amounts of aluminum for the structural components in their F150 trucks. The use of aluminum will reduce the truck weight by approx. 700 lbs and therefore increase the truck's gas mileage.


THE ROOT CAUSE OF WELD PROBLEMS IS ALWAYS INTERSTING, AND THATS WHY I CONTINUE TO TALK ABOUT THE FORD EXECUTIVE MANAGEMENT DECISIONS THAT WILL LIKEY INCREASE THE MANUFACTURING - PRODUCT LIABILITY RISKS WITH ONE OF THE WORLD'S BEST SELLING VEHICALS.

When any company makes a major vehicle change from carbon steel parts, to aluminum parts, the future weld product lability consequences that will occur from vehicle collisions should be given serious consideration. Poor robot MIG weld quality and weld repairs on high strength carbon steels is one thing, while in contrast, poor or inconsistent quality welds on aluminum parts, should always evoke greater concerns. Also the additional weld heat influence from what is likely to be poor weld repairs made on top of poor aluminum welds, should make any engineering mgr or designer increase their sleepless nights.

I would guess that the senior managers and engineers at Ford that made the decisions to switch to alum, were likely individuals that were not aware about their companies never ending, daily weld issues and lack of controls with their robot, MIG and resistance, carbon steel welds





Dec 2013:
A HEADS UP FOR THE LEGAL PROFESSION. Legal issues may eventually arise with vehicles that are involved in collisions, and those vehicles have large amounts of aluminum in their structures. Anyone with a fundamental knowledge of welding and metallurgy would possibly wonder what the EXTRA WELD HEAT influence from the aluminum repair welds would have on the structure's weld's Heat Affected Zones, and on the origional design strength of the aluminum components. Lets face it, you would have to believe the aluminum weld structure integrity was originally tested and approved on alum parts that had Sound, Single Pass welds.



Ed set the worlds first multi-robot cell
welding a large alum fabrication.



I have much interest in robot alum MIG welds, as i was the first person in North America to set complex, multi-robot MIG welds on large the large, aluminum robot application shown above.

In the late 1990's when pulsed MIG equipment was little more than electronic junk and alum wire feedabilty was a major issue, I managed to avoid the multi-robot cell, robot down time, and also avoid the weld quality - productivity issues and weld repairs you would expect. To achieve this, I simply used my process control expertise and my best weld practices.

For robot MIG issues in the auto - truck industry, you may want to visit this section.

For bad welds in the auto - truck industry. you will find data here


 

In my home section two, (link at bottom of this page), and in the MIG aluminum section at this site, there is much more information on the subject of Aluminum MIG weld fabrication issues and my resolutions.


WITH THE MAJORITY OF AUTO & TRUCK PLANTS AND THEIR SUPPLIERS, YOU WON'T HAVE TO LOOK FAR, TO FIND THE EXTENSIVE WELD COST CONSEQUENCES THAT WILL DAILY RESULT FROM UNDER QUALIFIED MANAGERS, ENGINEERS, TECHNICIANS & SUPERVISORS.

in 2014, WITH 20 MILLION VEHICAL RECALLS, AND BILLIONS OF DOLLARS SPENT ANNUALY ON RECALL REPAIR COSTS, IT WOULD SEEM THAT WELDING IS JUST ONE PROCESS, THAT THE AUTO - TRUCK MANAGERS AND ENGINEERS HAVE MANUFACTURING ISSUES WITH.


ONE COULD ASK. WHY THE INDUSTRY TRAINING IS NOT BEING PROVIDED SO INDIVIDUALS CAN BUILD AND BE RESPONSIBLE FOR, COMPONENTS THAT ARE ACTUALLY BUILT IN COMPLIANCE WITH THE DESIGNER'S SPECIFICATIONS.

MOST MANAGERS INVOLVED WITH WELDS DO NOT LIKE THIS SITE, THEN AGAIN, MOST MANAGERS WON'T VISIT THIS SITE AS THEY ARE TOO BUSY PUTTING OUT THEIR WELD SHOP FIRES.

In the last three decades, at many of the major auto - truck plants that I was asked to assist with their robot or manual MIG - Flux Cored weld quality and productivity problems, I was asked to create reports showing the root causes of the weld quality or productivity issues. In my reports provided to the plant managers and engineering managers, I would typically criticize the fact that the weld issues were not generated on the shop floor, they were instead generated by the lack of management - engineering, robot and weld process expertise, ownership, responsibility and accountability. Typically my reports would end up in the front office garbage baskets, and I even tho I quickly solved the weld problems for a small costs, I was rarely asked back.



There are many USA, auto - truck plant managers that will sweep their robot weld issues under their office rug. Other manufacturing executives may give up on the robot welded parts, and decide to send the parts to Mexico, or to some other country where overtime rates and manual labor weld repair costs, are not relevant.




We could all bury our heads in the sand while the USA middle class way of life quickly erodes.



With MIG and Flux Cored weld technology, from the 1950s to the 1980s, the USA led the industrial world in MIG equipment technology and in Flux Cored weld consumable development.

The MIG and Flux Cored process in 2014, accounts for approx. 80% of the global welds made daily. The irony with these two important weld processes, is in 1960's there was minimal focus by weld educators and by engineering management on Weld Process Controls and Best Weld Practices expertise, and fifty years later, little has changed. The one thing that has changed today in the weld industry, is the weld cost competitiveness, of today's global weld shops.

As most countries can do it cheaper than the USA and Canada, North American mfg managers and engineers would benefit by applying a controlled approach to the welds they daily produce. It's important that those that make a living from applications that involve welding, take note that the common, annual weld fabrication profits and job related erosion is not a recent thing.

The reduction in weld jobs and weld profit erosion has been occurring in North America for more than two decades, (thanks Reaganomics). While many involved in weld shops, complain about the influence of competing countries who pay welders and fabricators 25 cents, to three dollars an hour, it's notable that in 2014, that many third world countries have the engineering and manufacturing capability to produce any code quality, manual or automated welds.

One of the prime reasons many companies invest in welding robots, is to hopefully reduce their manual weld labor costs, and to provide consistent, optimum weld quality. The reality with the majority of companies that have invested in the robots, is due to the lack of management, engineering MIG - robot weld process controls expertise, most of the global robots purchased rarely attain more than 60% of their daily MIG weld production potential. To add to the production woes and costs, the typical robot down time of 30 to 60 minutes per shift is completely unacceptable, and also the usual high weld reject and weld rework costs, all add the robot woes.

It's not just the third world labor costs that North American large weld shops should be concerned about: If you work in North America, you will likely be aware that there are plenty of weld shops in the USA southern states that will be glad to weld anything for less than ten bucks an hour. In this increasingly difficult and frustrating industrial mfg weld cost environment, it's difficult to comprehend why so many weld shop managers, supervisors and engineers show so little little interest in MIG - Flux Cored Weld Process control and Best Weld Practices expertise.

It's not all doom and gloom however, for those North American weld shops that employ a manager, engineer or owner that do have an interest in improving their daily MIG - FCA weld quality, decreasing their weld failure liability and increasing their weld shop profits, the weld cost reductions and weld quality improvements are relatively simple to attain.

IT DOES NOT MATTER IF YOU MANAGE A WELD SHOP IN INDIA, CHINA, OR THE USA, THOSE WELD COSTS WILL EAT THE WELD PROFITS.

To get rapid weld quality and productivity results, takes a certain type of manager or supervisor.
[] It will take an individual who understands the value of weld process - equipment ownership.
[] It will be an individual who does not want to rely on inexperienced weld sales reps for weld advice.
[] It will be an individual who does not accept that skilled weld personnel have to "play around" with their MIG or flux cored weld controls.
[] It will be an individual who is honest about the fact that he needs to know more about the real costs of the common MIG - Flux Cored welds they are daily responsible for.
[] It will be an individual that understands there has to be value in weld process control - best weld practices expertise.


WHY SHOULD ANY NORTH AMERICAN OR EUROPEAN FAB SHOP MGR COMPLAIN ABOUT COMPETING LABOR COSTS, IF THAT MGR DOES NOT FULLY UNDERSTAND THEIR REAL MIG OR FLUX CORED WELD COSTS, AND DOES NOT UNDERSTAND THE WELD PROCESS CONTROLS - BEST WELD PRACTICES NECESSARY TO CONSISTENTLY PRODUCE WELDS AT THE LOWEST POSSIBLE COSTS?

I WOULD THINK THAT ALL MANAGERS WOULD WANT THOSE INVOLVED IN WELD DECISIONS TO WALK ONE PATH THAT LEADS TO TO THE IMPLEMENTATION OF UNIFORM BEST WELD PRACTICES.

Who benefits from the expertise offered at this web site? Welders, managers, supervisors, technicians, engineers, QA personnel and of course any person that has influence on the welds produced.

I HAVE BEEN IN HUNDREDS OF WELD SHOPS IN 13 COUNTRIES, AND NEVER WENT IN ONE THAT I COULD NOT INCREASE THE DAILY MANUAL OR ROBOT, MIG OR FLUX CORED WELD DEPOSITION RATES FROM 25 TO 70%. THE WELD COST REDUCTIONS WERE SIMPLY DERIVED WITH MAKING CHANGES TO THE WELD PROCESS OR TO THE WELD PARAMETERS UTILIZED.

The long winded message at this web site is necessary as the weld issues are global and they have gone on through the fifty years I have been optimizing welds. The message is not about what the low wage countries have the potential to inflict on the North American weld manufacturing industry. The message is about what the North American managers, engineers and supervisors have for decades, failed to do, and what they actually could do with virtually no costs to dramatically improve their weld quality and profits.



Welcome to weldreality.com, which I suppose has been a web weld blog since 1997. My name is Ed Craig. Many of you will know me from the 18 years I wrote the QA Weld Column in the USA Weld Design and Fabrication magazine. Perhaps you read one of my thirty plus published articles on the simplification of manual and automated MIG and Flux cored weld process controls. If you have a Machinery Handbook gathering dust on your shelve, and it's not too old, I wrote the MIG and cutting sections. I have written three books on MIG and Flux Cored Weld Process Controls and Best Weld Practice. With fifty years of hands on weld process control expertise, I have resolved manual and automated weld issues in more than a thousand companies in thirteen different countries. I hope you enjoy this web site which simply provides my personnel opinions on the importance of Best Weld Practices and Weld Process Controls for the welding industry.:


Note: In 2009 I was in Europe helping a compnay called Cameron. This company was a subsea valve manufacture. I was asked to assist them with their automated Hot Wire TIG clad weld issues. While in the UK, I heard about a unique weld process called TIP TIG, and a few months later with my business partner Tom O'Malley, we bought this important process to North America and to Australia.

When you visit tiptigusa.com you will find that TIP TIG is the natural evolution of the seventy year old TIG process. This process delivers 100 - 400% more hourly production than regular TIG, its much easier to use than TIG, and attains superior weld quality than any other weld process. If you weld alloys this process also delivers the lowest possible weld heat and the least possible weld fumes. I am proud that I bought this process to the USA and many of the worlds leading engineering companies are pleased that they have now found TiP TiG.



There are weld quality requirements that are impossible to attain with any MIG, mode, regular TIG, or flux cored, and that's when you turn to TIP TIG.

 



Enlightened engineers at Siemens found there were numerous TiP TiG benefits on their P91 - duplex pipe welds. Note Ed and his mate Tom O'Malley introduced this important weld process to North - S. America and Australia,



MOST IN THE WELD INDUSTRY DONT LIKE CHANGE, THEREFORE I SUPPOSE NO ONE SHOULD BE SURPRISED AT WHY OVER THE LAST FOUR DECADES, THERE HAS BEEN LITTLE EVIDENCE OF WELD PROCESS EVOLUTION:

There is a simple prime reason in the last four decades, why the industries that utilize MIG and Flux Cored have been slow to evolve. From Trade Schools, Community Colleges to Universities, weld educators have in general failed to present effective MIG - Flux Cored weld process control - best practice education and training programs.



This is not a message you will get from your friendly weld equipment supplier.

The influence of "Weld Salesmanship" has for decades negatively impacted the global weld industry and had grave weld quality, productivity, liability & cost consequences.





Manual MIG welds accounts for approx. 60 - 75% of the global welds produced, while the flux cored process which uses the same MIG equipment, accounts for approx. 15 - 20 %. The growth of the MIG process was in the 1980's further enhanced with the introduction and rapid annual growth of MIG welding robots.

SKILLS ARE JUST ONE OF THE MANY REQUIREMENTS FOR OPTIMUM WELDS. While the skills required for MIG and flux cored welds are quickly learned, manual and automated weld quality and productivity will only be optimized when the owners and users of these important weld processes have MIG Weld Process Controls and MIG Best Practices knowledge.

When weld decision makers lack MIG - Flux Cored Weld Process Controls - Best Weld Practices expertise, they will often turn to a weld salesman to provide solutions for their never ending daily weld issues. This situation has led to a highly technical industry that has an extraordinary reliance on sales advice. The result of too much global weld sales input, has resulted in decades of unnecessary weld quality, weld productivity and weld cost consequences.

Many managers, engineers and supervisors responsible for weld departments that contain robots, are under the impression that a skilled MIG welder will benefit those robot welds. These weld decision makers seem unaware that while the automated MIG equipment has the potential to provide superior weld quality and productivity than manual welders, the MIG weld optimization will not occur unless the worker who provides the automated - robot weld data fully understands the complete requirements of MIG Weld Best Practices and MIG Weld Process Controls.


Note: It's important for managers not to confuse WELD SKILLS with weld process control expertise. There will be many weld decision makers that come to this site who will be thinking, "in our shop we have highly skilled MIG welders". Please be aware that weld skills have never had anything to do with Weld Process Control expertise and Best Weld Practices knowledge.





Check out all the Weld Programs at weldreality.com.





The best possible robot MIG welds, would require a low cost, traditional CV MIG weld power source, a simple two part argon CO2 gas mix, the selection of the "correct" size MIG weld wire, and lets not forget the the important requirement of an "individual who has robot programming and MIG Weld Process Control & Best Weld Practice expertise".

As that MIG power source in the robot cell requires electronics to interface with the robots, the MIG equipment mfgs load up this equipment with numerous electronic bells and whistles which push up the weld equip prices and bring no value to most robot cells.




Ed made these 3/8 single pass fillets with the following.
.

Ed's Robot / Manual, MIG and Flux Cored Best Weld Practices and Weld Process Control Training Programs.

|

When the Chinese build any large scale project involving extensive welds, no one should be SURPRISED IF THE CHINESE ENGINEERS EVER FIND OR REPORT A BAD WELD.





Will those extremely poor welds that were made on the Beijing, Birds Nest Olympic Stadium, mean that one day this impressive steel structure will turn into a spiders web?

 





Written by Ed Craig.
Posted. www.weldreality.com. Aug. 2. 2008.

The five hundred million dollar, Beijing, Olympic stadium was built on top of an earth quake fault. The steel stadium is wrapped in a unique designed, high Strength steel cocoon that weighs approx. 45,000 tons. While the world's focus was on the unique design of this stadium, my focus was on the sad weld practices used to build it.

At the end of July, two weeks before the 91,000 seat stadium was ready to host the 2008 Olympics, I sat in front of my TV and watched a Discovery Channel program about the stadium construction. The steel Bird's Nest design is without question a steel wonder to behold, however having a more than slight interest in welding fabrication you know where my focus was. While I watched the TV show that showed the construction, I did not like what I saw that was going on with the on site welders and their welds and I certainly knew that what the chief engineer at the site was saying about the welds, was simply a load of rubbish.

May. 2009. Beijing Update: Check out what's happening to this Chinese stadium, nine months after Ed wrote his opinions on the poor welds and construction at the Birds Nest stadium.

Major MIG equipment manufacturers like MILLER, ESAB, LINCOLN AND PANASONIC WILL ALWAYS, ATTAIN EXTENSIVE PROFITS FROM AN INDUSTRY IN WHICH THE MAJORITY OF WELD SHOPS SEEM HAPPY TO PAY PREMIUM PRICES FOR THEIR COSTLY, PULSED MIG EQUIPMENT, WHICH TYPICALLY IS LOADED WITH COSTLY, USELESS, ELECTRONIC BELLS AND WHISTLES.

If these weld shops spent $400 on attaining my weld MIG & FLUX CORED WELD PROCESS CONTROL - BEST PRACTICES RESOURCES, the weld shops would then have the keys necessary to consistently attain optimum, manual and automated MIG and flux cored weld quality and productivity at the lowest labor costs, with ironically the lowest cost weld equipment and consumables.

It was my job as the corporate Training and Weld Product Manager with companies such as Praxair, Airgas, AGA and Liquid Carbonic, to test MIG weld equipment and consumables that were available from companies around the globe. I did this for more than 25 years.

Today, as many of you are aware, in 2104, you can pay $3500 to $4500 for a traditional 450 Amp. CV, MIG power source, or pay approx. $6000 to $12,000 for that pulsed MIG power source.

For weld shop management that has no wish to waste their profits in weld rework and low weld deposition rates, the weld reality is this. With my MIG - Flux Cored Process Control - Best Practices and Self Teaching - Training resources available here, there will be many weld cost benefits. For example, in contrast to the widely utilized, costly, pulsed MIG power equipment, when welding carbon steels, alloy steels and stainless weld applications, the weld shop will attain the same manual or greater MIG and Flux Cored weld productivity with the same or superior weld quality, from the much lower cost, easier to maintain, easier to operate, conventional, CV. MIG equipment


$$$$$$$: To attain optimum MIG or Flux Cored weld quality - productivity on carbon steels & alloy steels, gauge to any thickness), in 2014, the new CV MIG equipment, should cost in North America, approx. $3500 to $4500 for American built, 350 to 450 Amp MIG equipment.



When employees lack MIG - Flux Cored, Weld Process Controls and Best Weld Practices expertise, weld shops will unfortunately, daily waste money on the following weld issues.

[1] MIG WELDS THAT ARE MADE DAILY WITH PROCESSES AND CONSUMABLES THAT HAVE BEEN AROUND FOR DECADES, SHOULD NEVER REQUIRE WELD REWORK OR WELD GRINDING. FLUX CORED MULTI-PASS WELDS WILL ALWAYS NEED GRINDING.

[2] MIG - FLUX CORED WELD SPATTER COSTS GLOBAL WELD SHOPS BILLIONS OF DOLLARS ANNUALY TO REMOVE, YET WHEN WELD PERSONNEL HAVE WELD PROCESS EXPERTISE, SPATTER IS EASY TO PREVENT, OR TO MINIMIZE.

[3] IN THE MAJORITY OF WELD SHOPS, BOTH THE MANUAL AND THE ROBOT WELD DEPOSITION RATES ARE RARELY OPTIMIZED. WHEN WELDS ARE NOT AT THE HIGHEST POSSIBLE DEPOSITION RATES, MUCH HIGHER HOURLY WELD LABOR COSTS ARE BEING GENERATED. WITH MY TRAINING PROGRAM, THE MAJORITY OF WELD SHOPS WILL HAVE THE POTENTIAL TO REDUCE THE WELD LABOR COSTS IN THE 20 TO 70% RANGE.

[4] PAYING UNNECESSARY HIGH MIG WELD EQUIPMENT COSTS TYPICALLY BY PAYING FOR USELESS BELLS AND WHISTLES, IS NOW THE NORM THROUGHOUT THE GLOBAL WELD INDUSTRY.

[5] MANY COMPANIES WILL PURCHASE UNNECESSARY CARBON STEELS, METAL CORED AND FLUX CORED WIRES, WHILE IN MANY INSTANCES, LOWERS COST MIG WIRES WOULD DO THE SAME JOB.

[6] MANY COMPANIES WILL PURCHASE USELESS THREE PART GAS MIXES THAT CONTAIN OXYGEN WHICH BY THE WAY IS DETRIMENTAL TO MOST MIG WELDS. SAVINGS ARE ATTAINED BY USING LOWER COST, TWO COMPONENT ARGON - 10 TO 20% CO2, MIG GAS MIXES.

[7] MANY COMPANIES WILL PURCHASE ADDITIONAL ROBOTS WHEN THEY HAVE NEVER ATTAINED THE FULL WELD PRODUCTION OR QUALITY POTENTIAL OF THEIR EXISTING ROBOTS.

ALL OF THE ABOVE, ARE ADDRESSED WHEN THE WELD DECISION MAKERS HAVE THE WELD PROCESS CONTROL EXPERTISE THAT IS AVAILABLE IN MY TRAINING RESOURCES.







MIG gas selection confusion has for decades had tremendous weld cost and quality consequences for the global MIG welding industry.




The good news for the weld industry. When there is management confusion in a weld shop, it's then easy to create large weld cost savings.


It's a weld reality, that the global weld industry could save hundreds of millions of dollars daily if the majority of managers that influence the weld decisions learnt to to take ownership of their weld equipment and the processes and consumables that are vital to their organization. Also its common sense that in their role as a professional, these same managers should be capable of managing a weld shop without weld advice from a weld sales rep. Weld shops need to be managed and supervised by weld decision makers that can make rational weld shop decisions that are based on technical substance. To optimize weld quality, weld decision makers need to be aware of the process controls and best weld practices. To control weld costs, the weld decision makers should understand for each common weld, the weld deposition potential of the weld consumables and weld transfer modes utilized.

You would think it would make sense that all weld decision makers are aware of the real world costs of the common MIG and flux cored welds they daily produce.


It's common in many companies to see increased growth of Metal Cored and Flux Cored wires that typically can cost in the range of $2.50 to $7/lb. These are products that I have evaluated and tested for decades. The cored wires are mostly used for steel welds made in the flat and horizontal weld positions. The reality is that irrespective of what the company who uses these wires has been told by a salesman, when welding on clean materials, the welds produced with the cored products , do not offer in contrast to MIG wires that cost approx. $1/lb any real weld quality - productivity benefits. You may not take my word for this message, however with weld process control expertise, you would be aware of the truth of the statement. I believe that the use and continuing growth of the costly metal cored - flux cored consumables throughout the global weld industry is strictly a result of weld salesmanship.

For those who have never met me, it's important that you understand I have been optimizing MIG and flux cored welds in more than 1000 plants for more 5 decades. I also have been testing weld equipment and consumables for the same time period. Irrespective of the weld application I worked on, I have always achieved the highest possible weld quality - productivity, with no weld rework or weld spatter issues. The welds I produced were and still are attainable with process expertise and the utilization of the lowest cost MIG equipment and consumables.

Note: If a company wants to know how much weld salesmanship has had an influence at their plants, all any manager, engineer or supervisor has to do is think about all the MIG gas Mixes that they have tried in the last few years, and then take a look at MIG mixes in the cylinder storage racks. No matter what steels are MIG welded, any company that has used or is using a "three part gas mix", or is using more than two MIG gas mixes in their plants, has been influenced by MIG gas salesmanship. In 2013 there are now as many MIG gas mixes available in North America and Europe as there are breakfast cereals available on the shelves of your local super market.



COMMODITY PRODUCT PRICES ALWAYS BENEFIT WHEN THE CUSTOMERS ARE CONFUSED.

ONE WAY FOR THE MAJOR MIG GAS MANUFACTURES AND SUPPLIERS TO GET HIGHER PRICES FROM THEIR COMMODITY MIG GAS MIXES, IS PROVIDE SALES INDUCED, BOGUS WELD CLAIMS ABOUT THEIR THREE PART MIG GAS MXES. THE WELD REALITY IS THE THREE PART MIXES PROVDE NO REAL WORLD WELD BENEFITS FOR MOST STEEL AND STAINLESS WELDS AND THE MAJORITY OF TWO PART MIXES ARE SIMPLY NOT REQUIRED.




Global MIG gas misinformation and gas selection confusion has been the norm for more than five decades. It's a sad reflection of the weld industry that the majority of the MIG gas information found in weld shops is based on weld management, engineering, and supervision MIG process ignorance, and off course the info they do have has typically been provided by a weld gas salesman.

Is your company part of the global 3 part MIG Gas Mix Con Game? For any company that utilizes any three part gas mixes for carbon steels, alloy steels and stainless applications, they may be embarrassed to find out they have been part of an industrial gas marketing con game. For a few years I was on the American Weld Society (AWS) committee that wrote the USA. MIG Gas Specifications. Much of my time at these meetings went into trying to keep the extensive sales biased, incorrect data on three part mixes out of this important weld specification.

2013: Note: Many of the past AWS spec committees on weld consumables were made up with members that had a marketing or sales management background and they were typically responsible for the sale of products that were part of the specifications under discussion.

Apart from my work with the AWS MIG specification, in the last three decades, in my research roles at Airgas and AGA I developed four of the most practical, low cost, two component MIG gas mixes which are today sold throughout North America. If you want to stop wasting money on three part mixes, check out my low cost MIG gas mixes. For MIG gas information without sales bias, visit the MIG Gas section at this site.


For five decades all i ever heard in those weld shops was, "why change the way we have always done it".




OVER A 50 YEAR PERIOD, I HAVE BEEN IN A APPROX. 1000 MANUAFCTURING PLANTS IN 13 COUNTRIES, AND NOT ONE OF THOSE PLANTS HAD EVER REQUIRED THAT THEIR MANAGERS, ENGINEERS, SUPERVISORS, TECHNICIANS AND WELDERS HAD MIG & FLUX CORED WELD PROCESS CONTROLS & BEST WELD PRACTICES EXPERTISE.

THOSE IN WELD - MANUFACTURING MANAGEMENT WHO MAY HAVE HAD MINIMAL INTEREST IN "WELD PROCESS CONTROL EXPERTISE", SHOULD REVIEW THE FUNDAMENTAL WELD PROCESS CONTROL QUESTIONS IN MY WELD TESTS, AND CONSIDER THE COST RELEVANCE AND CONSEQUENCES OF THOSE QUESTIONS TO THEIR ORGANIZATION.

Ed's MIG Weld Process
Controls & Best Practice Test.


How much do you know about MIG - FCAW Process Controls - Best Weld Practic. The bottom line is Universities, Colleges & Training Facilities, don't
provide the weld industry with the process resources they need.


Ed's Flux Cored Weld Process
Control & Best Weld Practice Test.



 

A LACK OF GLOBAL FOCUS ON THE ESSENTIAL REQUIREMENTS
FOR PROCESS OPTIMIZATION:


The wide use of MIG welding started in the 1950's, yet since it's introduction, there has been little management, engineering or educational focus on the requirements for "MIG Process Controls and MIG Best Practices Expertise" in the shop. For the last sixty years the majority of global manual MIG and flux cored weld personnel have "played around" with their MIG or Flux Cored weld control
s.

Why do the majority in this technical industry accept LOWER TRAINING AND EDUCATION STANDARDS THAN MOST OTHER SIMILAR SKILLED TRADES?

When will the manual - automated global weld management start to realize that there is more to MIG welding than "skills" . If a machine shop supervisor won't put up with one of his machinists playing around with their Lathe or Milling machine controls, why would any experienced weld supervisor, manager or engineer allow weld shop personnel to play around with two simple MIG controls, two controls that in reality have hardly changed in the last six decades? The answer to this old problem is simple, those involved in weld management, supervision and weld education have simply not been aware of the requirements for MIG process controls and best practices. Weld process education has to start in the engineering office and with the weld eduction facilities.

WHILE THE MOST IMPORTANT WELD PROCESS UTILIZED BY ROBOTS IS THE MIG PROCESS, FEW MIG WELDING ROBOTS WILL EVER ATTAIN THEIR MAXIMUM WELD QUALITY - PRODUCTIVITY POTENTIAL.

Why would any company that takes pride in it's level of manufacturing and weld expertise, spend thousands on robots and then let their workers play around with the robot weld data.

There is a simple low cost solution to the global lack of Weld Process Control Expertise and lack of uniform Best Weld Practices. During the last four decades, I developed the world's most simple, self teaching MIG - FCA weld process control training program using my Weld Control Clock Method. With no previous MIG process control expertise. these process resources will within a few hours enable you or your employees (without taking notes) to have all the MIG - Flux Cored process control and best practices expertise necessary to instantly set correct, optimum weld parameters for any manual - automated MIG / Flux Cored steel applications.

ROBOT WELD PRODUCTVITY ISSUES, WELD QUALITY CONCERNS,
WELD REWORK & ROBOT DOWN TIME.

To attain optimum "robot" MIG weld quality and productivity or instantly deal with robot weld issues that effect down time, requires MIG Weld Process Control expertise. With the global average robot MIG weld production efficiency range at only 40 to 60% of it's real potential. With the too frequent questionable weld quality and costly robot weld rework usually in the range of 20 to 100%, many manufacturing companies would with the expenditure of $400 on my self teaching and training resources have a great opportunity for dramatic robot weld cost reductions and robot weld quality improvements.

For a few years, I was the North American Robot Welding Manager for ABB Robotics where I established the world's first Robot MIG weld Process Control Training Program. For the last decade as a consultant I have provided both manual and robot weld optimization and training to numerous companies in 13 different countries. Before I optimize a companies's robot welds, I start out by providing my Seven Steps to Robot MIG Process Controls Training Program to all the weld decision makers at the plant. I will not provide this type of training unless all the relevant management and engineers attend the program as lack of management - engineering weld equipment - process ownership has been and still is a major part of this global problem.

Note: I developed my programs so that anyone (no weld expertise required) could present them.

Why not provide your employees with my easy to use Robot or Manual, MIG or Flux Cored, weld Process Control" Training Program, and also take a look at my Self Teaching MIG and flux cored weld process control books and CDs. Imagine after a few hours of viewing this unique resource, that all the participants will have the ability to instantly address their daily robot or manual MIG weld issues which impact the daily weld quality and productivity. Imagine, there will be no one in the weld department "playing around with weld parameters" and imagine the plant management satisfaction in daily achieving consistent, optimum weld quality / productivity without weld rework all at the lowest possible weld costs.


A BIG MYSTERY IN MOST GLOBAL WELD SHOPS IS THE REAL
cost of the most common MIG weld in the shop.


MIG AND FLUX CORED WELDS AND COSTS? An organization cannot control it's MIG and Flux Cored weld costs unless someone fully understand the processes. One of the world's most common welds is a MIG or flux cored 3/16 or 1/4 (5 - 6mm) fillet weld. Do you believe anyone in your front office or on the weld shop floor can look at the weld wire, the MIG wire feed control and the weld size and instantly provide the real weld costs associated with that fillet weld. Yet the weld reality, using my process control resources, this weld cost task would be so simple that the weld decision maker would not even require a pen or calculator.



When you ask a manager the cost of a MIG or flux cored weld, the majority of managers typically will want to talk about the cost of the weld gas mixes and the cost of the weld wires. Many weld supervisors think they are on top of the weld production as long as they see that the welder's shield is down and weld smoke and sparks are being generated. What the supervisors and management is often not aware is the welder working hard can weld a vertical up flux cored 1/4 fillet at 6 lb/hr, or with process expertise they could weld the same fillet with the wire feed set to deliver >10 lb/hr. Also that MIG welder working up a sweat can weld that common, horizontal 1/4 (6 mm) fillet at 6 lb/hr or with the same sweat using my MIG process control data and weld that fillet at 12 to 20 lb/hr.


The weld reality is few managers or supervisors understand the weld deposition rate potential of the weld process and consumables they most use for the applications they daily weld. It's a sad reflection of the industry that i love that you will find that less than five percent of managers and supervisors will have the MIG - FCA process control knowledge and expertise necessary to optimize their weld quality and control and understand their real weld costs. That's the bad news and the good news is the solution is a simple one. My unique, low cost weld process control training resources enable the attainment of consistent, optimum MIG and flux cored weld quality and productivity for the majority of weld applications and also these resources simplify all weld costs.


The shortage of MIG and Flux Cored welders has
always been a global myth:

Pick up a weld magazine in any country and you will frequently read about how the majority of weld and manufacturing managers are concerned about the so called global shortage of qualified MIG - TIG or Flux Cored weld personnel?

If a company was required to increase it's MIG or Flux Cored weld labor force for a contract to weld Caterpillar equipment parts, or for welding ASME. 5G, duplex pipe for Siemens or Dow Chemical, It would find that hiring experienced welders was not a simple task. However the management and especially the management in the HR department would typically not be aware that if they simply could find people without drug problems and with a good work ethic, that any person with decent MIG skills and a good personality could with utilizing my MIG - Flux Cored Process Control Training resources, find that it would take approx. 40 - 60 hours to train a "none welder" for the welds. Those going through the short length training would have the capability to provide optimum MIG and Flux Cored welds that would meet any global weld code / specification requirements. Of course these same companies could also have the trainee weld personnel attend the usual local weld training establishment and after six months you would find that the new welders have a few skills and will "play around" with their MIG and flux cored weld controls.

THE TRADITIONAL TIG PROCESS REQUIRES THE HIGHEST WELDER SKILLS AND FOR SOME IT MAY TAKE MANY YEARS TO MASTER CODE PIPE WELDS. A SOLUTION TO THE SKILLS ISSUES IS A PROCESS I INTRODUCED TO NORTH AMERICA, THE PROCESS IS CALLED TIP TIG.

WITH TIP TIG, YOU COULD TAKE SOMEONE WHO HAS NEVER WELDED PIPE, AND IN APPROX 10 DAYS, THAT PERSON SHOULD BE ABLE TO MEET ANY ALL POSITION, CODE, PIPE WELD TEST.

By the way, those TiP TiG manual or automated pipe welds will be better quality than any regular TIG welds and the TIP TIG welds will be done 200 to 400% faster with superior metallurgical properties.

Your company has a large MIG or flux cored weld project coming up and will need to hire many more welders. In the past when the welders have taken the test between one and three out of ten will pass the tests and extensive costs are occurred in this frustration task.

If you want to increase the rate at which weld personnel can pass any weld qualification test, it would make sense if the weld decision maker in charge would insist that before the welders waste the weld costs associated with welding - testing the coupons, they sit them down and give them a few hours of the specific process controls and best weld practice requirements .




While 40 to 60% of most MIG welds would have defects that are not considered acceptable, over 90% of these weld defects will never be revealed as the majority of MIG welds are not made to weld specs that require "internal weld evaluation".



In contrast, API-ASME-AWS - NACE-ABS, codes require optimum Flux Cored - MIG - TIG - SMAW weld procedures for qualification, yet every code weld that has failed or has serious defects are welds that were typically made with so called, optimum, pre-qualified weld procedures and skilled welders.

Apart from the welder's skills, an essential element to the success of any weld project is the implementation of best weld practices and to ensure the weld personnel have weld process control expertise. I always find it interesting in the weld shops I visited to watch the weld personnel respond to the numerous variables such as weld gaps to mill scale, that daily influence the welds made.

Apart from the welders "playing around" with their MIG or FCA weld controls, how would the weld personnel in your shop respond to the following?;

[] welds with excess root gaps,
[] welds with joint misalignment,
[] welds with poor weld edge preparation,
[] welds with poor weld joint access,
[] difficult out of position welds,
[] welds on unacceptable surface conditions,
[] welds with crater problems,
[] welds that are causing distortion,
[] welds that are creating cracks, lack of fusion, porosity or spatter,
[] and lets not forget the ever the influence of welds made in changing environmental conditions.

A WELD REALITY: The solutions to optimizing weld productivity and preventing weld defects and weld issues is the one thing that most weld shops will never evaluate their employees or teach their employees. .

With all manual and automated welds, ZERO percent weld rework should be an easy goal for " professional weld decision makers".

I CALL THIS BEING A WELD PROFESSIONAL: While weld defects are influenced by many weld variables. All MIG - FCAW welders who have used my training programs should have the ability to instantly change their weld practices, weld transfer modes, consumables and parameters to deal with those variables and therefore prevent weld defects from occurring.

Every weld shop will derive tremendous quality - cost benefits from management, engineers, supervisors, technicians and employees who have been trained to be aware of the root cause of MIG and flux cored weld defects.

If you are a weld shop decision maker and you want to create cost affective changes in the weld shop, you have these two simple options;

[1] Get advice from another weld salesman.

[2] Or use the unique manual / robot MIG and flux cored weld process control training resources. available at this site.


 

WITH TIME, YOU WOULD HOPE THE WELD SHOP WOULD EVOLVE: You would find little difference in the weld issues generated in MIG weld shops in 2013, than those weld issues generated in 1963. It's been both unfortunate and costly for the weld industry that since the 1960s, the majority of weld shop decision makers have not been aware of the importance of weld process expertise or that MIG Weld Skills has had nothing to do with Weld Best Practices and Process Controls.

 

 

Ed's simple Weld Clock Method. Set that MIG pipe root or common 16 gauge sheet metal weld at 10 o'clock with 17 cups of coffee, (17V).




Ed's easy to remember Weld Process Control
Weld Clock Method© is Copy Right Protected.





ED'S MANUAL - ROBOT, MIG & FLUX CORED WELD BEST PRACTICES AND WELD PROCESS CONTROL SELF TEACHING AND TRAINING RESOURCES:

If you are teaching yourself or providing weld process control training for others, Ed's weld process controls and weld best practices resources are the key to attaining optimum manual and robot MIG and flux cored welds.

Item.1. The Book: "A Management & Engineers Guide To MIG Weld Quality, Productivity & Costs"

Item 2. A unique robot MIG training or self teaching resource.
"Optimum Robot MIG Welds from Weld Process Controls".

Item 3. A unique MIG training or self teaching resource.
" Manual MIG Weld Process Optimization from Weld Process Controls".

Item. 4. A unique flux cored training or self teaching resource.
"Optimum Manual and Automated Flux Cored Plate and Pipe welds.

Item 5a."Proceso de Soldadura MIG Manual" (MIG Made Simple.
Self teaching in Spanish)

Item 6a. The Self Teaching MIG Book/ Video. (MIG Made Simple in English).



Ed's Process Control Books
and CD Self Teaching - Training Resources.





The global weld cost consequences from "Hands Off" management - engineers.

The weld shop practices that for decades may have been influenced by inexperienced, hands off management, engineers and supervisors, has for many global plants, created an interesting weld shop culture that leads to extensive weld quality - cost consequences.

For those of you with sparse grey hair, you will have likely noted that in too many weld shops there is a glass wall that divides the hands off management and engineers from the weld shop floor. That dividing wall has often resulted in the "them versus us syndrome". In this costly and unhealthy manufacturing environment, it's not uncommon to find the crew (welders) has taken over the ship. You then end up with welders who do their own thing and develop inflated egos in from the control they have in the poorly run weld shop. This old and very tired weld shop quagmire is ripe for the influence of a weld salesman and ripe for weld quality issues and weld costs which are out of control.

WELD PROCESS CONFUSION HAS FOR DECADES OPENED THE DOOR FOR THE WELD SALESMAN:

Weld shop confusion will often lead to a costly crutch such as the introduction of new weld equipment saturated with useless electronic bells and whistles or unnecessary costly weld consumables. Lets face it, if that new pulsed MIG power source does not help the weld issues, the problem must be with the weld gas and the solution must be in that new three part gas mix. I have been in many weld shops in which the weld distributor salesman spends more time on the weld shop floor than the manufacturing manager.

Weld process confusion always enables DRAMATIC WELD COST SAVINGS:

The good news, it's taken decades to create the cultural weld shop mess we too often see today, however with management driven change, there typically is great opportunity for most weld shops to attain dramatic weld quality improvements and cost savings.

2013: PROCESS CONTROL IGNORANCE AND APATHY. FOR FIVE DECADES YOU WOULD FIND IT IN THE WORLD'S LARGEST ENGINEERING COMPANIES OR THE SMALLEST WELD SHOPS:

In the majority of fortune 500 companies in which welding is an important process, you will find that too often there is management - engineering weld process ignorance and apathy.

Most of you who have spent 10 minutes at this web site will now be e aware of the extensive lack of weld management in the Auto - truck industry, and It may be a surprise to find that many major USA fortune 500 companies such as General Electric and Dow Chemical have numerous fabrication facilities which appear to be stuck in a 1960 - 1970 weld manufacturing time warp. These corporations typically rose to greatness as a result of research, innovation and strong management and engineering leadership. In the last decade, as I visited many of the 500 companies to assist them with their never ending weld issues, I frequently witnessed the growth of hands off managers - engineers, with minimal focus on engineering R & D. Also thanks to the management weld apathy i found that the manufacturing practices - processes and procedures I reviewed were typically established in the 1960 - 1970s. The reality was while the past practices built these corporations, too many managers and engineers are today ensuring often through fear of change or lack of balls, that their companies will remain entrenched in that welding past.


IF A WELD SHOP IS NOT EFFICIENT IN TERMS OF THE WELD QUALITY - PRODUCTIVITY IT PRODUCES, HOW CAN THAT SHOP UNDERSTAND OR REACH IT'S REAL PROFIT POTENTIAL:

In the last 15 years, the North America, management and engineering weld process ignorance - apathy has been a large part of the discussion and scope of this site. Many people are not aware that an important consequence of the the lack of management focus on this important subject is this is one of the reasons the "USA no longer produces good paying factory weld jobs".

APATHETIC DOW MANAGEMENT AND THEIR TYPICAL "ENGINEERING WHY SHOULD WE CHANGE ATTITUDE":

So a fabricator I know in 2010 received an opportunity to quote on a job for Dow Chemical. Dow wanted large, thick wall, stainless steel, storage tanks. When the DOW welding specs were reviewed by the fabricator, he noted with dismay that DOW has requested the worst possible weld process for this large project. Dow wanted the fabricator to use the SMAW (stick) process to weld the 15 - 30 ft diameter tanks. The fabricator complained to Dow engineers and managers responsible that the use of the SMAW process would dramatically increase the weld production times and the welding costs. He also told the engineer that with the SMAW process, the anticipated weld rework costs would be much higher than they need to be if alternative welding processes were utilized. The fabricator requested that DOW enable them to uses the Gas Shielded Flux Cored weld process. The FCAW process would allow the fab shop to reduce the overall weld costs by at least 70%, provide higher weld quality and reduce the concerns for the production deadlines.

The Dow engineers and the management responsible for the project rejected the gas shielded flux cored selection recommendation. The reason give by the DOW management was an old tired one. Dow stated that the initial tanks which were first built in 1960s were welded with the SMAW process, and the engineers were therefore reluctant to change to the 30+ year flux cored wires. One of the DOW engineers actually had the nerve to say "after all why should we change the way we have always done it" . The DOW management - engineering response had and I am sure for decades has had dramatic cost - quality and schedule consequences for their company. Engineers or managers that do not utilize the most cost effective weld processes for their applications should do the fabricating industry a favour, and change their profession. Perhaps these people would be better suited working at McDonald's, as that's one company who would appreciate "this the way we have always done it".

I have seen the same apathetic management, and engineering process attitudes and apathy at most of the Fortune 500 engineering companies that I visited. To name a few, Dow, GE, Haliburton, Exon, ABB. All of these companies employed too many hands off, managers and engineers that were happy in front of their computers, and when it came to welding were even happier behind their glass walls. When engineers and managers lack weld process control expertise they would typically avoid making weld decisions that involved different weld processes. Lets face it, if management and engineers at any large corporation wanted to dramatically reduce their annual, global weld costs, these guys would have to first grow some balls, second, get a process education, (10 hrs of reading) and then take ownership and real responsibility for their large scale weld projects.


Extensive cost consequences
from this common global attitude.


Weld QUALITY & COST CONSEQUENCES FROM:

Lack of Management Weld Process Ownership.

Design & Engineering Weld Process Apathy.

Managers, Engineers and Supervisors reliance on sales advice.

Lack of utilization of Best Weld Practices.

Lack of use of weld Process Controls.

Weld Cost Ignorance.

Liability consequences from weld failures.







The dubious weld quality standards of the auto - truck industry:

An internal MIG weld evaluation would reveal that for every four robot MIG welds found in the auto - truck industry, typically at least two to three of the welds would reveal unacceptable lack of weld fusion or excess weld porosity.






The weld reality of the the majority of robot MIG welds that join global cars and truck parts, is the average weld size is approx. 4 - 5 mm, while the average gage part thickness welded is less than 1.2 - 3 mm. Thanks to the general lack of best weld practices and lack of MIG process control expertise in these industries, it's too frequently that the "over weld" rather than the robot or manual MIG - FCAW weld integrity is what is holding together those >$15K to $50K vehicles.

 


My manual and robot Weld Process Control Training resources are easy to learn and simple to use. These resources will ensure the personnel in your organization always attain the full weld quality - productivity from either your manual welders or from the robots and MIG equipment selected. Click here for info.



 

2008. Above Photo: When I had to use the ridiculous Miller remote control to set a Miller Axcess Pulsed MIG power source that was loaded with useless electronic bells and whistles, I knew that Viza, the tier one Spanish auto seat manufacturer must have purchased this new pulsed MIG equipment, based on the advise by a salesman. As I found out at Viza, the Miller Axcess equipment had a electronic problems that I had also encountered with problem welds in the USA Miller ignored the pulsed MIG problems with their equipment in North America and introduced it's Spanish customers to the same electronic problems. Check the MIG equipment selection for more info on companies that know they have weld equipment issues and make no attempt to tell their customers.



For many companies, this would be a first.

Where are the qualified global weld managers?

Those global, career web sites, will in a few minutes let you know how unimportant a "Weld Managers " job is.

A visit to one of the world's largest career web sites, monster.com and a quick key word search for a "QUALITY MANAGER" and you should find the this site will typically provide numerous jobs in the USA and around the globe. However if the key words, "WELD MANAGER" were used, typically less than five global jobs will be evident.

From my weld shop logic, it's always been more important to "prevent weld defects rather than to find them," and a weld shop manager, QA person, engineer, supervisor or technician that wants to justify his wage should know how to achieve this. The problem in the global weld industry is no more than 10 percent of this industry has weld personnel that have Weld Process Control Expertise.

Note. The sad weld reality is most large weld - fab shops will have a QA manager who will have inspectors reporting to him. The inspectors unfortunately will be typically are trained to find, rather than to prevent weld defects. We are all aware that Weld Process - Best Practices expertise should start with engineers, however as many of you will be aware, most of the major, global universities that provide weld engineering degrees do not provide their weld engineer students with the appropriate weld Process Controls - Best Practices education they need for the most common weld processes.


THE WELD SHOP PROOF ABOUT THE GENERAL LACK OF WELD PROCESS CONTROL EXPERTISE, IS USUALLY REVEALED BY THE LACK OF SOUND, UNIFORM, CONSISTENT WELD PRACTICES IMPLEMENTED IN THE SHOP:


Weld shops in industrial nations should never forget that they are in a business in which optimum MIG - TIG - Flux Cored weld quality and productivity is easy to attain in any third world weld shop that will pay it's welders less than $3/hr. As we are all aware, in North America we will often have the highest weld labor costs combined with weld management and supervision that has the least awareness of how to control those costs and optimize the weld quality and productivity. For those of you having an acid attack, take a time out, chew on a TUM and try not to blame the messenger. Lets face it, you are at this site because you want to improve something in your weld shop or improve your weld career prospects. The resources to do those are available at this site.

 

It does not matter if the weld issues are generated by the;
[] The PARTS.
[] The FIXTURES.
[] The ROBOT TECHNICIANS.
[] The PERSONNEL MAKING THE DALOY ROBOT WELD CHANGES.
[] The ROBOT CELL OPERATORS.

THE RESPONSIBILITY FOR ROBOT WELD QUALITY OR PRODUCTIVITY ISSUES SHOULD ALWAYS BE WITH THE PERSONNEL IN THE FRONT OFFICE.

Few in the global manufacturing industry are aware that for almost three decades in manufacturing facilities, over 90% of MIG welding robots were set up by inexperienced robot companies and integrators. The robot weld quality - productivity achieved after installation was further negatively influenced through management and supervision weld process ignorance, and through the plants inexperienced robot technicians.

The majority of global MIG welding robots are daily managed by technicians who are typically responsible for placing the weld data in the robot programs, yet the irony is that the vast majority of robot technicians have never received MIG Weld Process Controls and Best Practices Training.

When you combine the common lack of robot weld process controls - best practice expertise with;

[a] management that is typically not aware of the real robot weld quality - productivity and costs,
[b] equipment that is in the robot cell that is part of the problem, (Pulsed MIG weld equipment),
[c] equipment that is not in the cell that should have been part of the original robot purchase,
(robot TCP controls, torch cleaning or joint tracking etc),
[d] the too common, poor or lack of engineering and manufacturing standards that result in unacceptable "part dimensional tolerances" for the welds,
[c] the frequent poor weld fixture design that either impedes the robot movement or the optimum gun angles, or fixtures that do not provide consistent part placement,
[d] poor robot cell fixture maintenance.
All of the above will influence the global excess weld costs that are found with the majority of robot MIG weld cells.

I would not waste energy asking a designer of an auto or truck MIG welded parts, if they understood the process they had requested to weld their parts.


From car seats to car frames or shocks, thin wall tubes are widely used with car and truck parts. The tubular parts are great for increased strength and part stiffness, however these components also offer unique robot MIG weld - energy concerns. It's a shame that most of the university educated designers of the tubular parts will be completely unaware of the MIG weld requirements and the MIG weld concerns.

A good example of a tubular MIG weld problem will often occur with the "J" groove tube joint shown in the right photo. The J groove occurs when welding a round part to flat gage part. With this joint increased weld mass is necessary to fill the groove, which typically requires twice as much weld as necessary for the thickness welded. The larger weld mass dissipates some of the energy that would typically be applied to attain the required side wall weld fusion. Lack of MIG weld fusion is common with these weld joints, as is excess weld heat.

FROM WELDING THIN GUAGE PARTS TO 1/4 ((6.4 mm) FILLET WELDS, FEW WELD SHOPS HAVE EBER UNDERSTOOD THAT TOO OFTEN THE "MIG PROCESS DELIVERS A POOR RATIO BETWEEN THE WELD ENERGY PRODUCED, THE WELD MASS PRODUCED AND THE WELD SPEED REQUIRED.

Combine the frequent poor MIG weld fusion on J groove joints, with the short cycle weld times found with the common, "short length", auto and truck welds, and you often end up with rapid freeze, low energy welds that on the surface may look sound and robust. However as in the case of the weld macro above, you end up with a 1.4 mm tube to brkt weld that reveals, lack of robot MIG weld fusion. Note with the above poor weld fusion you have evidence of excess weld heat from the large HAZ evident on the thinner tube. This defect is a common MIG weld issue which is easy to resolve with MIG weld process control expertise. It's also something that one day hopefully designers of these parts will have a better awareness of.

Remember, J grooves welds typically require > 100 to 200% more weld necessary for the part thickness welded. Oversize MIG welds will take away from the weld fusion potential, slow down the robots weld speed, add to the excess heat in the welds HAZ, something that can weaken the HSLA parts.


If designers of robot MIG welded components do not purchase the robot process control - best weld practices program at this site, who will teach these personnel to understand the weld cost & weld quality consequences of their designs?

MANY AUTO INDUSTRY WELD SPECS HAVE THE NERVE TO SPECIFY WELD POROSITY CONTENT WHILE THEY KNOW THEIR WELDS WILL BE PLACE ON PARTS THAT HAVE BEEN IMMERSED IN OIL OR PARTS THAT HAVE GALVANEALED OR GALVANIZED COATINGS.

Also on tube welds it's difficult with some robots to control the robot Tool Center Point and attain consistent robot high rotational weld speeds from the robot's multi-axis movement and, or the fixture movement. The weld quality and consistency of the robot programming, the global lack of weld process control expertise with robot operators, the common small weld lengths, the weld parameter influence from MIG wire stick variations, and the weld wire helix issues can all influence the weld quality attained on small round welds.

Note: With tubular welds or cold rolled part welds, weld fusion - porosity issues is too often influenced by lubricating oils from the manufacturing - forming process, or from the zinc protective coatings on the parts.


As mentioned small tubular welds are often over sized welds and these Reverse Polarity welds will rapidly build up weld heat in a small localized areas. On thin gage HSS tube steels, the excess weld heat in the HAZ has to be a concern especially when additional weld passes are delivered from weld rework which is typical with auto and truck robot applications. To retain some of the High Strength Steel (HSS) structural integrity in the weld's heat affected zones, it's critical in the robot welding of these high strength components, to ensure that correct weld sizes are applied and manual MIG weld rework is eliminate. Also what's the sense of providing robot welds if they don't consistently provide weld fusion over their total length.

The HSS, small tube robot weld application, is one that management is advised to keep their inexperienced millwrights, electricians and other maintenance personnel away from. Robot welded parts don't need inexperienced maintenance personnel "playing around" with the robot weld data making "unqualified weld changes. The weld solutions to all of these issues are addressed in my robot MIG weld process control training resources.


TUBE WELD CONCLUSIONS: It's fine for designers and engineers to talk about the reduced weight benefits of their thin, high strength, steel or tubular parts, however if the weld process destroys those properties with unnecessary weld heat or lack of weld fusion, or if the manufacturing engineers have lost dimensional control of the parts creating weld gaps, your company will be producing welds with unacceptable quality. If this is the case (lawyers involved in car and truck collisions take note), what's the real benefit of the high strength tubular steels or any car - truck steels especially with those involved in vehicle collisions?

Successfully welding auto - truck components and avoiding future weld failure liability consequences, will come from designers, engineers, management and robot weld personnel who understand the robots, the weld processes and consumables used. All engineers and robot weld decision makers working with robot welded part should be aware of the fundamentals in my Best Weld Practices and Robot Weld Process Controls Training Resource.



Robots, weld costs & poor weld production efficiency:

i have been in hundreds of plants in 13 countries that use MIG welding robots and in the majority, it's typical to find the plants will use three robots to do the work that two could do. The managers and engineers in these plants will not be aware of this costly fact as they do not understand the process requirements necessary to attain optimum robot weld production without weld rework.

For more than two decades in the auto / truck industry, the typical, high volume, robot weld down time per-8 hr/shift has been a ridiculous 60 to 90 minutes, which according to Detroit auto industry sources, can result in an approx. cost of $2000 - $2500 per-hour. In my numerous visits to Detroit plants that were having robot issues, I found few managers or engineers understood the root cause of their robot weld issues and and even fewer wanted to get involved.

2013. The average global, robot MIG weld production efficiency range is 40 to 65% and the average robot weld rework range is 20 to 100%.



The last thing a weld shop needs is to ask weld QA personnel who typically have no weld process control expertise a question on weld process quality - productivity issues. QA personnel who are process control experienced are typically wasted in the majority of weld shops as the management and engineers direct them to react after the welds are complete.

For decades too many global manufacturing companies have placed their weld quality labor resources and focus on "finding weld defects" rather than on providing their employees (including QA personnel) with highly cost effective weld process control training programs, that would "enable weld defect prevention".

 

THE "GLOBAL WELD QUALITY DEMISE":


There has never been a bigger demand for QA Managers and Weld Inspectors, yet the demand for Weld Managers, Supervisors and Technicians with Weld Best Practice Capability and Weld Process Control Expertise has always been almost none existent.







[] IS YOUR ORGANIZATION CLOSE TO MAKING A LARGE WELD AUTOMATION OR WELD EQUIPMENT INVESTMENT AND YOU WOULD LIKE TO KNOW HOW TO ATTAIN OPTIMUM WELD QUALITY AND PRODUCTIVITY WITHOUT THE PURCHASE OF COSTLY, USELESS BELLS AND WHISTLES?

[] Do you have weld design concerns or looking for design tips that
can enhance weld optimization from your weld automation?

[] ARE YOU SIMPLY LOOKING TO RESOLVE WELD PROBLEMS OR LOOKING FOR THE MOST COST EFFECTIVE EFFECTIVE WELD PROCESS DATA AND PROCEDURES?

[] Perhaps you have a MIG / Flux Cored welder shortage at your locations and would like to provide the world's most effective robot - manual MIG process control training programs. With a few hours process training your employees will exceed your expectations.

AT THIS SITE YOU WILL FIND THE WORLD'S MOST EFFECTIVE MIG AND FLUX CORED PROCESS CONTROL TRAINING RESOURCES.


LOOKING FOR A LOW COST, FAST SOLUTION TO YOUR ROBOT / MANUAL WELDING ISSUES, CONTACT ED.

Ed has resolved weld issues for hundreds of companies and many of the weld issues were resolved with a phone call or by E-mail .

For info E-mail. ecraig@weldreality.com, call 828 337 2695




 


WHEN WELD MANAGEMENT DOES NOT RECOGNIZES THE IMPORTANCE OF WELD PROCESS CONTROL AND BEST PRACTICES EXPERTISE, THEIR WELD QUALITY - PRODUCTIVITY ACCEPTANCE STANDARDS WILL BE LOW. THE MANAGERS WILL KEEP HAVING UNPRODUCTIVE WELD ISSUE MEETINGS, ASKING THE SAME OLD IRRELEVANT QUESTIONS WHICH TOO FREQUENTLY WILL BE ADDRESSED BY THE LOCAL WELD SALES REP.

.

 


Manual or robots, it's the same MIG weld issues:



Do you know any tool maker or machinist that "plays around" with the settings on their equipment?


Be a professional like my grandson Riley. Train your weld personnel so they don't have to Ask a Lincoln Rep how to MIG weld a part someone likely MIG welded 50 years ago.




Does your weld facility employ weld managers, weld supervisors or FIREMEN?

In a weld manufacturing facility in which the MIG or flux cored weld quality and productivity are not optimized, it's not uncommon to find engineers, supervisors, technicians and their management in a constant Fireman mode, These are the guys that daily run around trying to quench the weld production and weld quality fires.

[] In the Fireman's plant, you will often find ISO deeply embedded, KAIZEN is a second language, black belts are in abundance, while many of the common manufacturing processes such a paint, resistance welds and MIG welds are out of control.

[] In the Fireman's plant, you will find the management and engineers are incapable of establishing uniform Best Weld Practices and have no understanding of the requirements of robot or manual Weld Process Controls.

[] In the Fireman's plant, you will not find a single person who can tell you the real cost of the common welds they daily produce.

[] In the Fireman's plant, you will the managers and engineers have not taken ownership of the manufacturing processes that are responsible for their profits.

[] In the Fireman's plant you will you will find no job descriptions or if there are job descriptions they are poorly defined.

How can any manager or supervisor control their weld costs if they don't know the real costs of the most common weld they daily produce?

How many weld decision makers have you ever met that can look at a simple 1/4 (6mm) fillet weld and the weld consumables utilized, and instantly know;
[a] the optimum consumables that should have been utilized,
[b] the optimum weld data that should be used,
[c] the weld deposition rates that should be attained,
[d] with robots, the weld speeds that could be attained for each weld.

REMEMBER, WELD SKILLS HAVE LITTLE TO DO WITH ROBOT WELDS: How many so called highly skilled MIG weld individuals with 20 plus years of weld experience are aware of the real world MIG weld process solutions to their common daily robot weld process issues?

Why bother with the costs and time associated with weld qualifications and weld procedures, if your daily weld results end up with "weld rework"?

Too many weld qualification tests and resulting weld procedures do not encompass best weld process practices or process controls. In north America, we loose over a billion dollars annual on weld rejects, unnecessary weld rework and poor weld productivity, and its a sad commentary that the majority of those welded parts will have had "pre qualified weld procedures". While so much reliance is placed on welding skills the experienced weld decision maker is aware that welding skills are only a small part of the requirements to consistently attain optimum welds.

The reason for most welds issues has always been a simple one and easy for any company or individual to rectify. As many of the individuals that set the MIG and flux cored weld procedures lack both weld best practices and process control expertise, they should simply order the relevant materials at this site, and spend a few hours with the materials. It's that simple.


For five decades, as I walked through more than a thousand weld shops in 13 countries, I hoped that in at least one weld shop, that I would find a weld decision maker who;

[a] could make weld decisions without seeking the advice of a weld salesman,

[b] understood the importance of weld best practices - process controls.

[c] was aware of the real weld costs.

It was a wasted effort. With my roles as a Weld Training Manger and Weld Product Marketing Manager for companies such as Praxair, Airgas, AGA, and Liquid Carbonic, I have dealt with, and trained more than 1000 weld salesmen and I therefore believe that this experience allows me to have an opinion on global weld sales reps.

Thanks to five decades of global MIG weld industry reliance on sales advice, three of the largest growth and most profitable weld products sold in 2013 for welding carbon steels are,

[1] Costly, unnecessary pulsed MIG equipment.
[2] Costly, unnecessary metal and flux cored wires for flat - horizontal welds.
[3] Costly, and unnecessary three part MIG gas mixes.


If the above three products were no longer available to the global weld shops that weld mostly carbon steels, low alloy steels and stainless steels, there would be no impact on the weld industry's weld quality and productivity.



As it was five decades ago and as it is in 2013, the majority of weld decision makers need to cut the umbilical cord which too often is attached to a local weld sales rep:

When MIG or flux cored weld advice is needed, many of the global weld shops which employ weld personnel who have been in the business for decades, will not think twice about asking a weld sales rep for advice. What's ironic about this statement is the majority of sales reps will have a background education or experience which is not relevant to the welding industry.

The sales reps with their too frequent biased product advice will usually be eager to recommend another new, useless three / four part MIG gas mix, or offer their costly pulsed MIG power source with it's useless, programmable magic wave forms, sensitive circuit boards and short life span.

If you want evidence of the MIG weld process and equipment confusion, you would find it in the majority of global weld shops.




TAKE A WALK AROUND THE WELD SHOP:
[] How many different MIG power sources, welding wires and gas mixes can you count? Try to figure out how many of these products have been tried or evaluated in the last few years?
[] Figure out how many welders in the shop are daily playing around with their MIG weld controls.
[] Ask yourself, why is their weld spatter on the parts?
[] Ask yourself, why do the welds lack uniformity?
[] Ask yourself, why are welds being rejected or require weld rework?
[] Try and find someone that can tell you the real cost of the most common weld in the shop.


How could any weld manager, engineer or supervisor maximize the weld profits, if they do not fully understand cost of the welds?

Few weld shops employ managers or supervisors that can in a few minutes work out the cost of a common 3/16 or 1/4 ( 5 - 6 mm) fillet weld. When asked about weld costs, the majority of global weld shop decision makers will want to discuss the cost of the MIG wires or the MIG weld gas mixes. Manual and automated weld deposition rate potential for the common MIG - FCA weld sizes is rarely given consideration or fully understood.

Note: If it takes you or anyone in your organization more than 5 minutes to work out the cost of any weld, that person lacks weld process control expertise. The solution to this striking weld cost issue is simple. Those interested, should spend a few hours with my low cost MIG - Flux Cored weld process control - best practice resources. A few hours to get complete control of any MIG or flux cored weld cost.



WHEN MANAGERS LACK WELD PROCESS - EQUIPMENT OWNERSHIP AND WELD ISSUES OCCUR. THE MANAGERS WILL TOO OFTEN FOCUS ON THEIR WELD PERSONNEL RATHER THAN ON THE REAL ROOT CAUSES.





Optimum MIG - FCA welds are made by stupid machines, when Best Weld Practices and Process Control expertise is applied.

 


The MIG process is over fifty years old, yet I wonder how many weld decision makers in a weld shop would be able to answer the following fundamental weld questions.

HOW IMPORTANT WOULD THE FOLLOWING FUNDAMENTAL WELD PROCESS CONTROL QUESTIONS BE TO ANY ORGANIZATION THAT WELDS?




Test your Weld Process Knowledge with these fundamental weld questions. If it takes you more than 15 minutes to provide the "correct answers" to the following weld questions, you are not in control of the world's most common weld equipment and consumables.

[1] As MIG Spray Transfer is the most widely used weld transfer mode used for all steel welds on parts > 1/8 (>3mm) thick, it's reasonable, that the MIG weld personnel would be aware of the answer to this question.

What is the MIG wire feed setting in inch/min (m/min) in which the common 0.045 (1.2mm) wire using argon - 20% CO2 goes into Spray Transfer?

[2] Most MIG weld personnel are not aware that a change in MIG gas mixes requires a change in weld parameters. The weld supervisor wants to try another new MIG gas mix.

What weld parameter changes would a weld decision maker advice the welders to adjust with a change of the shops's MIG gas mix from argon - 20% CO2, to argon - 10% CO2?

[3] Utilizing the best weld transfer mode is the first step to weld optimization and a change in weld part thickness may enable a change in the weld transfer mode.

The welders in the shop usually weld thin gauge parts <3mm, with 0.035 (0.9mm) wire. Occasionally they have to weld thicker parts in the 3 to 12 mm range. Using an 0.035 (0.9mm) MIG wire, what wire feed setting in inch/min (m/min), will Short Circuit Transfer change into spray transfer when using argon - 20% CO2?

[4] One of the most common MIG gas mixes utilized, causes many weld problems.

Why is the common argon - 25% CO2 mix the worst possible MIG gas for companies who
weld parts thicker than 1/8 (>3mm)?

[5] Why purchase robots if there is little expertise on the robot weld speed potential?

Your company is using a robot to weld a common 3/16 (5mm) carbon steel, horizontal fillet welds.
An 0.045 (1.2 mm) wire and argon - 10% CO2 is used. To meet your weld production needs you need to attain a minimum weld travel speed of 40 ipm. Provide the

Wire Feed Speed____ inch/min. Required Amps ____ Volts___.

[6] Robot weld production is greatly influenced by robot down time.

The robot cells are on average going through three to six contact tips each day. The robot welds 1/4 (6mm) carbon steel, using an 0.045 MIG wire and argon - 10% CO2. The wire feed data is 280 inch/min (7 m/min) with 25 weld volts.

Why is this company having daily contact tip issues?

[7] Weld automation is rarely optimized if automated MIG or flux cored weld parameters are poorly understood.

A mechanized weld carriage or a robot is used to weld a 1/4 (6mm), horizontal fillet weld with an 0.045 (1.2mm) E71T-1 flux cored wire and argon 20% CO2. Provide the flux cored;
Wire Feed Rate____Weld Travel Rate____Weld Voltage____.

[8] Can the weld shop profits be maximized in a weld shop that does not understand the real cost of a weld?

What is the MIG weld cost for a weld application which has a total of 6 feet of weld (1.5 meters) of 1/4 (6 mm) horizontal fillet welds on each part. The part is welded with the common 0.045 (1.2mm) MIG wire. This wire cost $1 /lb. The argon - CO2 gas mix cost is $40 per-cyl. The wire feed rate used is 420 inch/min with 30 volts. The welders have an overhead rate of $40 / hr. The MIG welders average arc on time is 30 minutes per-hr.

[9] Gas shielded flux cored wire will not be optimized unless the parameters are understood.

Welding 1/4 (6.4 mm) structural carbon steel parts with an 0.045 (1.2mm) E71T-1 flux cored wire. The weld position is vertical up. The gas mix is argon - 25% CO2. Without asking the sales rep, provide the optimum wire feed, amps and voltage for the welder.

[10] Fine tuning MIG or flux cored welds is an essential requirement for anyone responsible for the welds.

This company has an automated Bug O type weld unit that runs on a track, (or the application could be robot weld). The MIG Spray Transfer weld is oversize. Without touching the wire feed rate, you increase the weld travel rate by 20%. What will you have to do to the weld voltage and explain why?

[11] So many companies use this poor MIG gas mix.

The weld shop is using Helium Tri Mixes (90 He - 7.5 Argon - 2.5 CO2) for MIG welding thin gage <3 mm stainless. As the new weld shop decision maker you have to advice why this expensive MIG gas mix has been the wrong choice?

[12] An important part of weld cost is the time spent cleaning those welds.

The weld shop is using MIG Spray and Pulsed MIG and weld spatter is in abundance. The weld decision maker is about to demonstrate how to get rid of most of the weld spatter. What will he adjust adjust and why?

[13] The weld shop welds thin gauge parts with short circuit (SC) and have extensive weld spatter. To get rid of the SC spatter, what parameters have to be adjusted and why? The same weld shop then welds using MIG spray transfer and also get spatter. As the weld decision, you have to explain why in contrast to the SC welds, you are about to make opposite weld parameter adjustments.

[14] In the robot cell a glob of weld on the wire tip is causing poor arc starts and effecting the robot weld production.

At the end of the robot welds there is a large melted glob on the end of the weld wire. The glob is causing robot arc start issues. Explain how the glob causes the problems and how you will get rid of the globs?

Note: A reasonable question. Are the above weld process control questions relevant to the weld quality, productivity and costs in a weld shop, and just as important are the questions relevant to your weld career? If you had difficulty with the fundamental MIG and Flux Cored weld process questions, don't feel frustrated, after all, for more than six decades the weld industry and most weld educators have placed minimal focus on the subject of weld process controls. The solutions are available in the training section of this site.

Ed's MIG Weld Process Controls & Best Practice Test.


Ed's Flux Cored Weld Process Control & Best Weld Practice Test.

It's unfortunate that the majority of weld decision makes will daily struggle for decades with weld problems that could easily be addressed with weld process control and best weld practices expertise.


You may know a WELD MANAGER, ENGINEER OR SUPERVISOR LIKE THIS.


This will be that manager, engineer, supervisor or technician that daily has their head buried in the sand. This is the weld decision maker who takes no ownership for the companies weld equipment and processes. This guy actually believes that MIG and flux cored welders need to "play around" with their weld controls and his companies daily weld quality and productivity depends on the temperament and artistic skill levels of each welder. This guy (most women would have more sense) will get most of his weld questions addressed by the local sales rep. This is that weld decision maker who believes that weld productivity is measured by how long the welder's hood is down, and never has had a clue about the cost of the welds he is supposed to be responsible for.

[] When you ask these weld decision makers about their weld costs, they typically want to discuss the cost of the weld wires and gas mixes.

[] When you ask these weld decision makers about their weld issues, they will not think twice about calling the local weld sales rep for advice. They will have no problem spending unnecessary dollars on the latest (useless) three part gas mixes, or on costly pulsed MIG equipment that is typically loaded with ineffective electronic bells and whistles.


These are the weld decision makers who will daily accept inconsistent, manual, weld quality and unacceptable productivity as being the norm.



Or you may know a WELD DECISION MAKER LIKE THIS:


[] These will be the weld decision makers who are tired with the daily, futile finger pointing, typically directed at those who are not responsible for the ever changing weld shop issues. These guys will also be fed up with the time wasting useless, too frequent weld meetings, in which BS is the norm, and practical, cost effective weld solutions are rare.

[] These will be the individuals who are frustrated that their so called experienced weld personnel have to "play around" with the decades old, two control, MIG and Flux Cored weld processes.

[] These will be the guys who no longer want to read weekly reports full of excuses for the inconsistent, robot or manual, MIG flux cored weld quality and productivity.

[] These are the weld decision makers that know that optimum MIG - Flux Cored weld process performance comes from the plants that will have the ability to establish uniform Best Weld Practices and Weld Process Controls.

[] These weld decision makers will know that to achieve optimum weld quality - productivity, their employees need more than weld skills, they need MIG - FCA weld process control training. Click here for my Weld Best Practice - Process Control Resources.


Note: You should not be in this industry if you don't have an open mind, a sense of humor, and very very thick skin

I hope you are not upset with the messenger at this site and that you are focused on the message. I hope weldreality.com can be a catalyst for progressive, cost effective weld changes for your organization. I also hope that my information and opinions will encourage managers, engineers, technicians and supervisors towards Weld Process Ownership. The info at this site can dramatically reduce most of the common MIG / Flux Cored weld process issues, the too common weld myths, the process - consumable weld confusion, and the too frequent sales reliance that's common for most global MIG weld shops.



EXON - HALIBURTON - GM - ROLLS ROYCE - IMPERIAL OIL - FORD - CHRYSLER HARLEY - DANA - MAGNA - TENNECO - VOLVO - TOYOTA - HONDA - IMPERIAL OIL - COMBUSTION ENGINEERING - GENERAL ELECTRIC - CATERPILLAR - JOHN DEERE - MERCEDES - DOW CHEMICAL - BABCOCK - ABB - GENERAL DYNAMICS - VW - TEXTRON - INGERSOLL RAND and ESSO are just a few companies that utilized Ed's robot / manual process control services, expertise or training resources.

Ed Craig provides weld process quality / productivity solutions for a reasonable fee. E-mail. ecraig@weldreality.com.

 

Ed's Robot and Manual MIG and Flux Cored Weld Process Control Training power point presentation should be provided to all personnel involved in the weld process and involved in weld process decisions. This list starts with the management, engineers, supervisors, technicians and QA personnel and of course all the weld shop personnel.

When everyone in the weld department walks the same welding path and training is provided, Uniform Best Weld Practices and Weld Process Controls can be implemented and the following should result.

[] All robot or manual pre-qualified weld procedures will provide data that deal with all the
real world parts and the weld variables that will influence the daily weld quality and productivity.

[] Optimum, shop floor Weld Manufacturing and Weld Instructions will presented. The management will ensure that these instructions will be adhered to and always highly visible.

[] All weld personnel will be aware of how to instantly set optimum MIG and flux cored weld data for any weld, any alloy, any wire, any weld issue. The change in the weld setting will be made without the weld personnel "playing around" with the weld parameters.

[] Daily weld clean up and weld rework will become miniscule and unacceptable.

[] Managers, supervisors or any weld decision maker will know the real cost of the common welds they daily produce.

[] All weld decision maker will be aware of their weld production capability in terms of the weld deposition rate potential and the weld travel speeds per their common weld applications.

Visit all of Ed's MIG and Flux Cored self teaching and Weld Process Control Training programs.

 

It's not just the global Auto - Truck industries where there is typically great opportunity for weld quality - productivity improvements and dramatic weld cost reductions.




Tremendous improvements in MIG - TIG and Flux Cored weld quality and weld cost reductions, can be found in the majority of global weld shops.




For Ed's Ship Yard, Oil Rig weld issues section, click here.


The greatest potential for weld quality improvement and weld cost reduction is found in every ship yard and oil platform mfg facility.


[] No one daily uses more MIG - Flux Cored weld wires than a ship yard or a facility building
oil - gas platforms.

[] No one daily produces more weld defects or has higher weld repair costs than these industries.


If a person wanted to find extensive lack of management, supervision and engineering "weld process ownership", the first place they would visit would be the above facilities. The next place to visit would be an automotive or truck manufacturing plant. The good news for those are looking for career opportunities and advancement in these industries, to rise above the common weld management - engineering apathy and mediocrity all that person would have to do is get weld process control and best practice expertise, grow some balls and be ready to show how they could generate tremendous weld quality improvements and weld cost savings.

Ed's Flux Cored Weld Process Control & Best Weld Practice Test.

In the weld cost section, take a look at the multi-million dollar cost savings, one ship yard attained using my one day flux cored process control weld training program.


As a weld process control expert, you should have the ability to instantly master any manual or automated weld equipment - consumables utilized, and without playing around with the controls, attain both optimum weld performance and productivity with all welds.

As a weld process control expert you know it's your responsibility to ensure the correct process control training is provided.

Imagine a weld shop in which all the weld personnel are aware of the root causes of the manual / robot MIG and flux cored weld problems, and these employees have the ability to provide instant, logical solutions to their weld issues, without playing around with the weld controls.

Imagine a weld shop in which all weld personnel understand the relationship between the wire type, weld gas, wire diameter, weld transfer mode, part thickness and the weld deposition rates and weld travel speeds required and the welders are also using the correct weld practices and techniques for the process and consumables utilized.

It's always "rare pleasure" to watch the weld personnel I have trained over the years when they act in a professional manner and instantly set optimum manual or robot weld parameters for their application.




Ed's MIG - TIG - Flux Cored Process Control Workshops:



Over sixty participants from six countries including Australia, England, Germany, Spain, Mexico and Canada, attended this one of Ed's work shops. The workshop seminar was called, "Seven Steps to Robot - Manual MIG Weld Process Controls".



For both Ford and and their tier one supplier Dana, this was a rare opportunity for their unqualified managers, engineers and supervisors to witness consistent, optimum, robot MIG weld quality on the truck frame lines.






A decade ago, my Robot Process MIG Weld Control training program dramatically improved the weld quality and productivity on the Ford F-150 truck frames. The
F-150 is the world's biggest selling truck.



E-mail. From Dana Weld Engineer To Ed Craig:


Jan 2007: Ed. I wanted to send update about the E-Town Dana plant that you visited a few years ago: As you know on your first visit to this plant, our robot lines were producing less than 40 truck frames (Ford F-150) per-hour and the majority of the MIG robot welded frames required extensive weld rework. Thanks to your MIG Weld Process Control Training and your consumable / parameter changes and recommendations, the results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We now daily attain our average goal of more than one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. Many thanks from a grateful Dana Corporation.
R. G. Dana. Weld Eng.

Note from Ed: It makes me happy to hear a robot welding success story like this, especially at Dana, where initially there was extensive management and engineering process ignorance, and process control apathy with great resistance to the robot weld changes I recommended. The Dana - Ford truck frame weld quality and productivity results were eventually attained through the weld process control and best practices training program I provided. This program is available in my Robot / Manual Weld Process Control Training CD programs located here.

 


LIKE MANY WELD SHOPS DOES YOUR COMPANY HAVE MONEY TO THROW AWAY? AN AVERAGE PRICE FOR A REGULAR, CV, MIG 350 TO 450 AMP POWER SOURCE, IN 2013 WOULD BE IS $2500 TO $3500. IN CONTRAST, THE TYPICAL PRICE RANGE FOR PULSED MIG EQUIPMENT IN THE SAME AMP RANGE IS TYPICALLY $5000 TO $12000.

MIG welding carbon and alloy steels? I hope you visit the pulsed MIG section to view why your company should not be wasting $5000 to $12000 on those pulsed MIG power sources.




WITH GLOBAL MIG PROCESS CONFUSION. IT'S NO SURPRISE
THAT THERE IS GLOBAL MIG WELD GAS CONFUSION:




There are approximately sixty MIG gas mixes available for MIG applications, which is ridiculous as no more than four MIG gas mixes should be required.

The common global MIG gas mix selection confusion is simply a reflection of the global weld industries lack of MIG weld process control expertise.




Ed Craig developed four low cost MIG gas mixes
that provide real world weld benefits.




Note:
Working in management with AGA, Airgas and Liquid Carbonic, Ed developed and introduced four of the top selling MIG gas mixes used today in North America.







MAY 2014;

MANUFACTURING AND WELD PROCESS EXPERTISE WOULD LIKELY SERVE COMPANIES BETTER THAN COMPLIANCE WITH INNEFECTIVE, ISO QUALITY STANDARDS:

A message to automotive management and engineers.

INSTEAD OF WASTING EXHORBANT COSTS AND VALUABLE MAN HOURS ON THOSE EUROPEAN GENERATED, BUREAUCRATIC AND OFTEN INNEFECTIVE, ISO QUALITY STANDARDS, MOST COMPANIES WOULD HAVE ACHIEVED SUPERIOR QUALITY RESULTS IF THE SENIOR MANAGEMENT HAD THE ABILITY TO HIRE 'QUALIFIED, HANDS ON MANAGERS WHO BELIEVE IN ACCEPTING OWNERSHIP AND RESPONSIBILITY FOR THE EQUIPMENT - EMPLOYEES THAY MANAGE'. OF COURSE THESE INDIVIDUALS WOULD ALSO HAVE THE UNUSUAL EXPERIENCE AND EXPERTISE NECESSARY TO TRAIN THEIR EMPLOYEES AND IMPLEMENT BEST PRACTICES.

For over two decades I've been reporting on the manual - robot weld issues generated by the apathetic, hands off, we accept no ownership weld management and engineers in the auto - truck industry. Here we are in 2014, and GM, the world's largest auto - truck company will loose billions of dollars on recalls of close to 14 million vehicles, (equivalent of a good years production). The irony is few consumers are aware that for every vehicle recalled there are numerous others that have factory induced defects that never get reported. While some may argue that cars today are complex and therefore we should expect many issues, my argument would be that sending a space craft to mars is complex yet engineers and managers seem to be able to handle that little project. Every product that goes into a car or truck is managed and engineered by university qualified individuals who's job it is to see that the products they put into the vehicles conform to the design and manufacturing specifications.

To show that we don't have this lack of management - engineering ownership and accountably disease in North America, we are all aware of the quality issues with Mercedes, and Toyota is a product that at this time carries lesser quality expectations than it did a decade ago. This last week in May, Nissan reports it will have to replace hundreds of its Nissan Leaf battery cars because of missing welds. The Nissan recall is because a key front structural component has not been completely welded. The missing welds would weaken the front and make it less able to protect the car's occupants in a crash.


When those Big Three automotive corporate executives lined up in like sheared sheep to borrow billions from American taxpayers to save their companies, a logical individual who knows this industry could have asked. Why does the auto industry, which has one of the highest ratio of engineers to workers, annually create "billions of dollars" in rework, rejects, recalls, warranty and productivity issues? In these industries, millions of dollars are lost daily from robot MIG weld rejects, excessive weld rework and poor robot weld production efficiency. We are all aware of the important role the MIG process plays in building a car, yet for approx. three decades, we have seen that the majority of auto - truck plant managers and engineers seem to lack the ability to understand what they own and simply lack the ability to establish uniform Best MIG Weld Practices and apply logical cost effective MIG Weld Process Controls to their plant's robot welds.

With automotive robot - manual MIG and resistance welds, it's not just the too common, missing vehicle welds that should be a consumer concern, it's the poor quality of many of the remaining welds that the customer never gets to see. The poor quality welds will for many generate serious consequences when that vehicle is involved in a collision.







TOO MANY WELD SHOPS EITHER HAVE NO WELD JOB DESCRIPTIONS, OR THEY PROVIDE POOR WELD JOB DESCRIPTIONS?
Weld quality and productivity issues will always be more numerous in weld shops in which confused managers, surround themselves with confused supervisors, who are surrounded by confused engineers, who have to be surrounded by confused employees. You can be sure these individuals will get no assistance from their none existing, or poor job descriptions: A well run weld shop starts out with all weld personnel having job descriptions that clearly identify their required expertise and their responsibility and accountability for the daily weld quality - productivity attained.


When the blind leads the blind, you know things cannot be as smooth as they should be.

FOR DECADES, UNQUALIFIED AUTO / TRUCK PLANT MANAGERS ALLOWED UNQUALIFIED MAINTENANCE MILLWRIGHTS AND ELECTRICIANS AND OTHER UNQUALIFIED PLANT PERSONNEL TO DAILY ADJUST THE SO CALLED "PRE-QUALIFIED WELD PARAMETERS" ON THEIR ROBOT MIG WELDS.


Joe, every time I walk past the robot cells, some millwright or electrician from the maintenance department is playing around with the robot weld data. For heavens sake Joe, our experienced welders play around with their MIG controls. Do you seriously believe those guys in the maintenance department with there 150 - 200 amp Miller MIG machine, have the MIG weld process control expertise necessary to optimize robot MIG welds? By the way Joe, in case we ever get sued for faulty welds, perhaps you can tell me why are these unqualified guys are changing the so called, "pre-qualified weld data" without engineering approval and new weld qualification?

If you are relatively new to the auto - truck industry take note that few Global MIG welding robots are well managed. "The majority of the technicians and engineers who run robots in this industry are simply "operating" not optimizing the equipment and the process. Any engineering survey would find that less than 5% of the personnel that daily make adjustments to the robot MIG weld programs are in full control of the robots or the process.

I made the above statement in a weld report that I provided to the Ford (Detroit) Frame plant management in the 1990s. It was futile message at that time as the managers and engineers running the plant simply did not understand the concept of weld process ownership and they also lacked the interest and knowledge to grasp the root cause of their daily robot MIG weld issues.



Below. A few of the work shop participants at Ed's 2007. This unique workshop was called, "Seven Steps for Robot Weld Process Controls". The location. Wolf Robotics. Colorado.




You can purchase Ed's Seven Step, Robot program for around $400. Any questions E-Mail Ed at ecraig@weldreality.com.

 


GM - FORD - HARLEY - DANA - MAGNA - TENNECO - VOLVO - TOYOTA - HONDA - IMPERIAL OIL - COMBUSTION ENGINEERING - CATERPILLAR - JOHN DEERE - MERCEDES - DOW CHEMICAL - ESSO BABCOCK - ABB - GENERAL DYNAMICS - GENERAL ELECTRIC - VW - TEXTRON - INGERSOLL RAND -

The above, are just a few companies
that utilized my Weld training resources.




Dec. 2013: THE USE OF ALUMINUM IN BOTH TRUCKS AND CARS, WILL FINALLY MAKE THOSE MANUFACTURING MANAGERS, ENGINEERS AND SUPERVISORS SEE THE LIGHT, AND ACTUALLY DO WHAT THEY ARE PAID TO DO.

Dec. 2013: It's interesting to see that Ford Motor company has decided to use aluminum for it's best selling F150 trucks. For three decades I have criticized the unqualified engineering and managers at many auto - truck plants for not understanding or practicing Robot Weld Process Controls (RWPC) and Best Weld Practices, (BWP). Ford's engineering management, and it's suppliers are going to learn very quickly, that any company that tries to robot weld high volume, aluminium applications without engineers and managers that have learnt RWPC and BWP will be a companies that never reach their full manufacturing profit potential, and companies in which few of the manufacturing managers and engineers involved will ever get a good nights sleep. Visit home section two below for more info on this important topic.





Thanks for sticking with it. The following is in the home page
Section 2.

[] Find out why the inspection approach of most QA weld managers is simply not cost effective.

[] View the best inconel, stainless, pulsed MIG "clad" welds that have ever been made in North America.

[] Find out why so many companies that do code quality welds are stuck in a 1960s weld time warp.

[] I found it amusing that Ford Motor company executives announced they were going to use aluminum parts for the F150 trucks, when for decades the managers and engineers at Ford and their suppliers struggled to attain optimum robot MIG welds on easy to weld carbon steel truck parts.

[] Find out why companies should not be using self shielded flux cored wires, when they want to attain quality welds and good mechanicals.

[] When the weld equipment and processes are not optimized you would think someone in management wants to generate change.

[] If you have any sense you don't make MIG welds like most Japanese manufacturing companies.

[] Find out why the "robot weld team" is frequently a good resource for the management to water down and spread out what should be their role and responsibility.

[] This North American car parts plant was unusual. I found two managers that showed an interested in the requirements necessary for optimum robot weld quality - productivity.

[] Find out why the Chrysler corporate management lost over 20 million dollars from bad welds on one easy to weld part.

[] Why the big three wastes millions of dollars each year for welder training.

Continue Home Page. Section. 2.


Or perhaps you are interested in seeing how easy it is to save millions of dollars with large weld fabrication projects take a look at the following;

HOW THIS SHIP YARD SAVED MILLIONS FROM WELD QUALITY - PRODUCTIVITY IMPROVEMENTS:

HOW THIS OIL COMPANY SAVED MILLIONS EACH YEAR FROM INCREASED PIPE WELD PRODUCTIVITY. Click here.

Low wages yet management pays ridiculous
prices for useless MIG equipment.

Aisan management loves to waste money on useless
MIG weld equipment electronic bells & whistles.

Visit Eds Process Training Resources.



Please don't leave this site without checking Ed's MIG- Flux Cored
best weld practices and weld process controls resources.


 

 




Email Ed Craig at ecraig@weldreality.com   -  Phone Eastern Time. USA.