Ed set the robot welds for Volvo Cabs, Corvette bodies, Harley bikes and Ford 150 truck frames.

Why would any manager allow weld personnel to play around with weld
controls and create welds with questionable weld quality.

For weld defect prevention requires unique robot - process solutions.

View the weld and provide the instant robot weld process solution.

E-mail from Johnson Controls Spain.
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
materials which I've been reviewing. I find the program really interesting and practical. Your approach to MIG weld process control is unique and it certainly works. From the advice you provise it would seem that you have been in our company as most of the robot MIG weld issues you address are part of our every day work here in Spain. Thank you Jose Moreno.

Note: Ed set optimum robot car seat welds for Johnson Controls in Mexico and optimized car seat welds for Toyota, Subaru, BMW, Peugeot, Volkswagen, Citroen, Ford and GM.

E-mail from Tenneco USA:
Ed. I just wanted you to know that Tenneco has plants all over the world. We have been very enlightened by your " Robot MIG Weld Process Control Training materials and we are slowly implementing your robot process control and best practice concepts to the shop floors.

E-mail from P&F. 12/07
Ed, you would be interested to know that by the end of the year I will have at least 100 of our robots welding with your recommendations of the 0.035 (1 mm) wire, conventional spray transfer with no pulsded welds. It took me 10 years Ed, but finally using the recommendations you made to us in the nineteen nineties. I now have the top guy in North America convinced traditional spray is the way to go with the robot MIG applications. In regards to your MIG process control training programs and resources we now have two other plants that will be contacting you.

Note from Ed: This tier one supplier to Honda and Toyota is the largest robot welded parts supplier in the USA. The plant has hundreds of Panasonic robots and Panasonic pulsed MIG equipment. The Panasonic weld equipment and pulsed process was a requirement of the Japanese parent company. For more than a decade, this Panasonic pulsed MIG equipment daily generated numerous pulsed weld and production issues that dramatically impacted the plant's daily robot weld quality and production. With all the problems, the blinkered corporate engineers and apathetic managers in Japan were reluctant to hear that the traditional, more durable, lower cost, North American CV equipment using convention spray transfer would provide highly effective solutions to the majority of their daily robot weld issues.


Note: At one time, I was the Weld Manager for the North American ABB Robotics Division. I was the first person in in the industrial world to establish a Robot Weld Best Practices - Process Control Training program. During my 40 plus years as a MIG weld process control expert, I have assisted over a 1000 companies in 13 countries in attaining both manual and robot MIG, TIG and flux cored weld quality and productivity optimization. In the last two decades, I have resolved numerous Motorman, Fanuc, OTC, Cloos, Panasonic and ABB robot weld quality and productivity issues.

Companies such as GM, Caterpillar, Case, Ford, Volvo, Tower Automotive, Magna, Dana, ABB, Babcock, Boeing, Delphi, TRW, Monroe, Johnson Controls, Textron, Genesis, General Dynamics, General Electric and numerous others have benefitted from Ed's training programs.

My robot training program has two different sections

[1] Covers the requirements for optimum Robot Weld Quality - Productivity on gauge parts < 4 mm. Welding gauge parts < 4 mm provides unique issues. When robot welding thin gage applications avoiding weld burn, attaining consistent, controlled weld fusion and minimizing distortion are important to decreasing robot weld rework. For thin gage welds, your robot personnel can utilize 4 common weld transfer modes, short circuit, globular, low spray data or pulsed. The issue many weld decision makers have, is which is the optimum weld transfer mode and which are the optimum parameters and weld consumables for those carbon steels and stainless gage welds. With my resouce your personnel will instantly select the correct robot weld data and consumables for any thin application.



[2] Covers the requirements for optimum Robot Weld Quality - Productivity on parts > 4 mm to any thickness.

Robot spray transfer and pulsed transfer welds on parts > 4 mm to any thickness requires unique weld fusion and weld deposition considerations. Ed established the robot weld data for the world's largest trucks manufactured by Caterpillar and set optimum robot data for the world's best selling truck frames, the Ford F150. Ed has set robot welds on ships, boiler walls, trains, pipe lines, oil rigs, farm and construction equipment etc.

EVERY WELD SHOP THAT UTILIZES ROBOTS SHOULD BE AWARE OF THE ROOT CAUSES OF ROBOT DOWN TIME AND THE REQUIREMENTS FOR CONSISTENT OPTIMUM WELD PRODUCTION.

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

Process Control training provides the ability to provide resolutions to weld issues. With a few hours exposure to this animated CD program, your employees will have the ability to provide instant solutions to things like:

[] Robots and Lack of Weld Fusion.
[] Robots and LAvoiding Weld Burn Through.
[] Robots and Weld Start Issues.
[] Robots and Optimizing Weld Tie Ins.
[] Robots and Avoiding Wire Burn backs.
[] Robots and Minimizing 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 Weld Porosity.
[] Robots and Weld Undercut.
[] Robots and The unique requirements for attaining high deposition and high speed welds.
[] Robots and The unique requirements for multi-pass welds.
[] Robots and Solutions to Variable Gaps.
[] Robots and Process solutions to Part Dimension Inconsistency.

INSTANT ROBOT COST WELD BENEFITS:

You can spend $12000 on a new pulsed MIG power source for your robot cell and still not attain optimum robot weld quality and productivity, or you can spend $395 on my robot weld training resources and see instant improvements.

When all your weld decision makers know how to fine tune and set optimum robot MIG weld data, the weld quality / productivity results will be both immediate and dramatic.

With weld process expertise, you will not require more weld trials to find optimum weld data, equipment or consumables. There will be no more time wasted playing around with weld controls. Imagine the benefits of having employees with the ability to instantly apply optimum process data that will ensure minimum robot downtime, minimum weld rejects and minimum weld rework. When those robot weld problems occur, you can call a team meeting or watch your trained workers instantly react with the correct weld process resolutions to the weld issues.

HOW EASY IS IT TO PRESENT THIS PROGRAM?

As Genie on the right did. The management ensures all the weld decision makers assemble in a lunch or training room. Place this CD in
a laptop. Project the program to the screen. The person who is presenting the data needs no weld process expertise. Provide two four hour sessions. At the session completion everyone who participated will have the necessary robot MIG instructions, best practices and data necessary to establish Best Weld Practices and implement Weld Process Controls. The training results will be immediate.

[] No more personnel playing around with the robot MIG weld controls.

[] No more exasperating meetings discussing weld issues that never
seem to get resolved.

[] A dramatic reduction in robot down time will be achieved.

[] Management will have less concerns for product liability weld issues.

[] Engineers will be aware of the real world part dimensional restrictions and weld gap tolerances for all robot MIG welds.

[] Minimum weld rejects and weld rework will be generated and when issues occur solutions are instant.

[] Maximum weld deposition rates for each weld with the fastest possible robot weld speeds.

[] Eliminate the influence of biased and innapropriate sales and vendor advice.

[] Provide logical justification for the MIG equipment and consumables purchased.

[] Your weld personnel will have the necessary expertise to establish highly cost effective, uniform Best Weld Practices - Process Controls for any robot application.

Think of the benefits of working in a manufacturing weld shop environment in which best practices without sales bias and optimum robot weld process controls are established. Your product liability concerns are reduced, and all the weld decision makers take a uniform, professional, practical approach to the daily attainment of optimum, robot weld quality and productivity.


Note: As this CD program simplifies process controls, and presents the answers to the majority of questions that could be asked, the person presenting the program needs no weld process control expertise.



E-mail: From Ryan at Dana Corporation USA:

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 Ford F-150 frames per-hour and the majority required extensive weld rework. Thanks to your robot weld process control / best weld practices training 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.

Many thanks Ryan Good Corp Weld Eng. . Dana Corporation.

2007: Update from Ryan. 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 ther process recommendations of an 0.040 wire and the traditional spray mode, instead of the 0.052 (1.4mm) wire and using the Rapid Arc (Lincoln's pulse program). Thanks again RG.