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Benefits to Automating

WELDING EQUIPMENT IS ONLY ONE PART OF OUR BUSINESS.

There are a great many benefits to automating your manufacturing process and it need not be expensive.

1

.

Increased Output:

A semiautomatic system has at least twice the output of a skilled welder.

2

.

Decreased  

Variable  

Labour  

Costs:  

A  

‘machine  

controlled’  

system  

always  

repeats  

the  

same  

welding  

parameters.

Reliance  

on  

the  

‘human  

factor’  

dramatically  

increases  

a  

manufacturer's  

labour  

costs.  

A  

fully  

automatic  

system  

with

sufficient stations can run at four or at eight times the pace of a skilled welder.

3

.

Improved   

Weld   

Quality:   

Mechanised   

welding   

delivers   

identical   

welds,   

improves   

weld   

integrity   

with   

accurate

consistency.  

Operators  

tend  

to  

"smooth  

over"  

mistakes  

with  

their  

torches,  

hiding  

lack  

of  

penetration  

or  

a  

possibly

flawed weld

4

.

Decreased  

Scrap/Rework:  

It’s  

never  

good  

to  

throw  

away  

parts  

with  

significant  

accumulated  

value  

as  

a  

result  

of  

an

operators lack of detail. Automating weld parameters and part placement decreases the error potential.

5

.

Easier  

to  

qualify  

a  

welder  

on  

approval  

test.  

The  

process  

relies  

on  

automated  

equipment  

rather  

than  

on  

operator

skill

6

.

Less  

welder  

fatigue.

  

The  

process  

reduces  

the  

amount  

of  

operator  

attention  

required.  

The  

principle  

task  

is  

to  

monitor

the automation weld

7

.

Difficult  

welds  

are  

easier.  

Tight  

clearances  

and  

hard  

to  

reach  

locations  

are  

the  

environments  

in  

which  

Orbital  

Welding

heads excel in

8

.

Remove the welder

from tiring, repetitive conditions and exposure to hazardous fumes

In some cases a few minor adjustments can:

1

.

improve or even reduce your overall welding consumable usage.

2

.

improve,  

minimise  

or  

even  

eliminate  

reject  

and  

rework  

rates  

and  

the  

need  

to  

scrap  

items  

by  

implementing  

systems  

that

will weld it right the first time round.

3

.

improve or ever eliminate pre-weld preparation steps

4

.

improve or even eliminate post-weld grinding of spatter and excess weld metal

5

.

improve and reduce the amounts you pay as a company on unnecessary and unplanned downtime and overtime

6

.

improve and even reduce wasted effort and unnecessary motions and delays

7

.

improve and reduce arc time

8

.

improve and reduce the cycle time and arc-on time

9

.

improve your operator factor (arc time / total labour time = operator factor)

1

0

.

increase your deposition rates/travel speed

1

1

.

eliminate the very sources of bottlenecks in your production facilities

1

2

.

eliminate activities that add no value

1

3

.

improve  

your  

operator  

efficiency  

by  

recommending  

equipment  

that  

are  

easier  

for  

operators  

to  

set-up  

and  

understand

thereby minimizing training time.

1

4

.

improve  

your  

operator  

efficiency  

by  

recommending  

equipment  

that  

maintain/ensure  

optimum  

welding  

parameters

(e.g., machines with parameter limiting/lockout features)

1

5

.

improve  

your  

operator  

efficiency  

by  

recommending  

equipment  

that  

will  

speed  

up  

your  

welding  

productivity,  

and

thereby eliminating the need to hire additional welders

1

6

.

help your company implement ‘leaner’ manufacturing techniques

AUTOMATION NEEDN’T BE EXPENSIVE – LET US SHOW YOU HOW

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