With a few hours exposure to this animated CD program, your employees will have the ability to provide instant 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 unique requirements for attaining high weld speeds

E-mail From Marcus di Sabella

Ed, I just received your process control materials and within five minutes n 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.

 

This program is applicable to all types of robots and weld equipment.

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.

Robots, Process Parameter and Consumable Choices. There are different weld transfer modes and consumable options available to the plant engineers and technicians for those robot welds on parts > 3 mm. 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 the spray or pulsed weld data on those carbon steels and stainless applications, this is the program for you. When should you use pulsed or spray? or when should you use an 0.035 - 0.045 and 0.052 (1- 1.2- 1.4mm) wire?

How many robot welds are set and the companies making the parts are not aware that the robot weld data is simply not optimum reference the weld quality or productivity attained? This CD provides the most comprehensive program ever developed on attaining MIG / MAG weld process optimization. The program provides the "Weld Clock Method", which Ed developed over three decades as a simple, unique solution for process optimization.

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, will 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.

Note. You need no process expertise to present this program, as all the data you will ever need is presented on the CD Power Point slides.

Don't play around with weld controls and settings,

provide instant solutions and avoid weld defects.

[] 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 process control 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.

E-mail. From Jose Ignacio Moreno. 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 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.

E-mail From: Tom Plummer: USA.

Good afternoon Ed.

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: From Dana Corporation Employee: 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.

Many thanks Ryan G!

A Grateful Employee
Dana Corporation.

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.

Ed set this robot to weld a 1 meter diam pipe.

1980s to early nineties:

[1] Ed was the first person in North America to set a robot to weld all position flux cored weld
for a 40 inch pipe line.

[2] Ed was also the first in the world to set ASME qualified robot pulsed MIG welds for the difficult task of welding boiler pipe to headers. Customer was ABB Combustion Eng.

[3] Ed was the first person in the world to set on site, robot Inconel / stainless pulsed MIG clad welds inside a water wall boiler.

[4] Ed was the first person in the USA to set a "multi robot line. 4 robots" to successfully MIG weld a large aluminum part. (golf car frame)

In the early nineteen nineties, Ed established
the multi-robot pulsed MIG data, for these aluminum golf cart frames.

This unique, robot weld process training CD program, can be two things.

[1] A tremendous resource when you need solutions for your robot weld issues.

[2] The world's most effective Robot MIG Process Control training program for all steel and stainless gage applications > 4mm.

This CD has 257 power point slides. For training you would require approx. 5hrs.

This CD provides all the information and tools necessary for managers, engineers, technicians, maintenance and QA personnel to;

[A] Take complete ownership of the robot welds.

[B] React in a uniform manner to instantly resolve robot weld performance, productivity / quality issues.

[C] Enable the establishment of uniform 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.

Back to Training materials. Click.

Email Ed Craig at ecraig@weldreality.com   -  Phone Eastern Time. USA. 828 658 3574