Untitled Document

[5] Robot MIG Process Controls for all Steel / Stainless Gage Applications < 4 mm, using Short Circuit or Pulsed Transfer.

An animated Power Point Program available on a CD.

Produced by Ed Craig. Price $189.

E-mail From Marcus di Sabella

Ed, I just received your robot process control materials and within five minutes of skimming I found many flaws in our weld techniques and process data. These materials will be very helpful to our organization!
Thanks for your expertise and prompt service!

Process Engineer.
Car Sound Exhaust System, Inc / Magnaflow Performance Exhaust.
Rancho Santa Margarita, CA.

What other resource will provide you with specific MIG/MAG process control
data and the root causes and solutions to MIG weld defects involving tubes or rods?

With a few hours exposure to this CD program, your employees
will have the ability to provide instant process solutions to:

[] Robots and Lack of Weld Fusion.
[] Robots and Weld Start Issues.
[] Robots and Weld Burn Through.
[] Robots and Wire Burn backs.
[] Robots and Contact Tip Issues.
[] Robots and Weld Crater Issues.
[] Robots and Weld Arc Start Instability.
[] Robots and Inconsistent Welds.
[] Robots and Poor Weld Profiles.
[] Robots and Weld Spatter.
[] Robots and Solutions to variable gaps.
[] Robots and Process solutions to part dimension inconsistency.
[] Robots and Weld Porosity.
[] Robots and Weld Cracks.
[] Robots and Weld Undercut.
[] Robots and The requirements for attaining high weld speeds.

Note: Ed has a reputation for weld process control simplification.
The weld decision maker who presents this presentation needs
no robot weld process control expertise.

Process Parameter and Consumable Choicess. There are many weld transfer modes and consumable options available to the plant engineers and technicians and those robot welds > 3mm. Many plants use the wrong size weld wires, or use weld transfer modes which are not optimum. This program takes the salesmanship out of process advice and provides the optimum weld transfer modes, consumables and weld parameters for all your steel and stainless gage applications.

If you want to eliminate robot weld personnel playing around with either spray or pulsed weld data on those carbon steels and stainless applications > 4 mm, this is the program for you.
[] When should you use pulsed or spray?
[] When should you utilize that 0.035 - 0.045 and 0.052 (1- 1.2- 1.4mm) steel / stainless MIG/MAG wire?.
[] How will , and how do you know you are at the optimum weld quality / productivity condition?

This CD provides the most comprehensive program ever developed on attaining MIG / MAG process optimization. The program provides the "Weld Clock Method", a unique simple approach to process control. Ed developed thee Clock Method over three decades. With this process control method, your weld personnel will have the three most important weld settings (the only weld settings that should be used) in their heads for any short circuit, or pulsed steel or stainless gage applications.

Root Causes of Robot Down Time and how to maximize Robot weld Production. The data that's presented in this program is extremely beneficial as few robots achieve their weld production potential. Being aware of the factors that influence your robot weld production potential and down time and providing instant solutions to the many daily robot weld problems, can have a dramatic impact on your weld quality and production costs. Once you present this program to your employees, typically you can anticipate a 20 to 50% increase in your daily robot weld productivity.

Don't play around with weld controls and settings
and end up with questionable weld quality.

[] Robots and Process & Consumable Choices: There are many weld transfer modes and consumable options available to the plant engineers and technicians for those robot welds. Many plants use the wrong size weld wires or weld transfer modes which are not optimum. This program takes the salesmanship out of process advice and provides the optimum weld transfer modes, consumables and weld parameters for all your steel and stainless gage applications.

[] Robots and Weld Rework: It's typical in many plants to find excess weld rework required for those robot welds. This program identifies the root causes deals with all the major issues that impact weld quality and rework.

[] Robots and Weld Defect Prevention. All the common weld defects are covered and the data is provided to ensure your defects are minimized and weld rework in minimum.

[] Robots Weld Deposition Rates and High Speed Welds: This training shows you how to always attain the maximum weld deposition rates for gage welds to any thickness and provides the data necessary to attain the highest possible robot weld speeds.

[] Designers and Manufacturing Engineers, Process Awareness: If engineers responsible for the parts and fixtures receive this training they could actually design parts and fixtures that enhance the opportunity for increased robot weld quality and productivity.

[] Robots and MIG Equipment: The training cuts through the sales bias of weld equipment and makes you aware of why Inverters and Pulsed MIG equipment can enhance weld quality on some applications and may have dramatic negative weld quality impact on other applications.

[] Robots and Weld Process Calibration: Few global robots have received correct robot / power source calibration. In attaining consistent daily weld quality and production performance the contractual requirements of calibration need to be understood by engineers and managers.

Ed. I work as manufacturing engineer in Johnson Controls Alagon (Spain). We mainly build car seat structures. And we have some robot welding cells. Last week I received your robot process control material, which I've been reviewing. I find it really interesting and practical. Your approach to weld process control is unique and it certainly works. It seems you have been in our company, as most of the robot MIG weld issues you address are part of our every day work.

Thank you JM.

Tenneco has plants all over the world. We have been very enlightened by your " Robot MIG Weld Process Control" training materials " We are slowly implementing your process control and best practice concepts to the shop floors.

Tenneco .USA.
Aug 2007:

E-mail July 06: From Dana Corporation Employee:

Jan 2007: Ed I wanted to send update about that E-Town 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 per-hour and the majority required extensive weld rework. Thanks to your robot weld process control / best weld practices program the results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames jobs 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 F-150 line.

March 2007: Update from RG. Hey Ed:
Just thought I would drop you a line and let you know that in the beginning of April we will be working on switching over the 5th Dana plant to your process recommendations of an 0.040 wire and the traditional spray mode instead of the 0.052 wire and Rapid Arc (Lincoln's pulse program). Thanks again RG.

Remember It's item # [5] Robot MIG Process Controls for all Steel / Stainless Gage Applications < 4 mm, using Short Circuit or Pulsed Transfer.

This unique, robot weld process training CD program, can be your resource when you need solutions for your robot weld issues or use it as a highly effective training program. This CD provide 253 power point slides which as a training program will require approx. 2 days. It will provide all the information and tools necessary for managers, engineers, technicians, maintenance and QA personnel to;

[A] Take full ownership of the robots and welds.
[B] React in a uniform manner to instantly resolve robot weld performance, productivity / quality issues.
[C] Enable the establishment of Best Weld Practices.
[D] Provide all the data necessary for the implementation of highly effective Weld Process Controls.

With this CD, an organization has the tools necessary to implementing cost effective Best Weld Practices and Robot Weld Process Controls. Cost $189.00