schweißtechnische lehr- und versuchsanstalt halle gmbh april 15 analyses of the cost efficiency...

Schweißtechnische Lehr- und Versuchsanstalt Halle GmbHSchweißtechnische Lehr- und Versuchsanstalt Halle GmbH

26. Apr 2023

Analyses of the cost efficiency while using GSI Analyses of the cost efficiency while using GSI SLV Welding Trainer in training of weldersSLV Welding Trainer in training of welders

Presentation of results

Michael Bednarzik, Hochschule Anhalt (Köthen)H.-J. Kaftan, Hochschule Anhalt (Köthen)Dipl.-Ing. IWE Silvio Schulz, SLV Halle GmbH

Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 2

Introduction of project

Goal of the project: Economical analyses of Virtual Welding Training Systems (GSI SLV Welding Trainer) in

comparison to the traditional training of welders.

Calculation of real data in terms of costs, enviromental conditions, health and safety and motivation.

Design: -Welding processes MAW und TIG-underlying training time: 1 week (5 days)-detailed recording of consumption of materials, consumables, gas, power etc.-consideration of costs for a welding instructor

Duration: April-Juli 2012

Project: Bachelor‘s Theses


Introduction

Virtual Welding Training Systems

versus

Welding booth


GSI SLV Welding Trainer - Overview

Arbeitsplatz Schweißtrainer

GSI SLV Welding Trainer & an additional Computer in order to use e-learning software.


Day-Sequence

-Boot up the computer / setup the training system-Introduction by the Welding Instructor (once)-Follow practices according the training program (curriculum)-Assess the computer scoring independently

-Duration of practices max. 1-1,5 hours

-Change to the separate E-Learning program -Learning theoretical basics by self-study

-Rotate between practices and e-learning all the day

Sequence of a training day at the GSI SLV Welding Trainer


Day-Sequence

-control welding machine (consumable, shielding gas etc.) -preparation (cutting base material, grinding)-introduction by welding instructor-demonstration -welding trial-follow up works (cooling test piece, fracture test)-evaluation of the test piece together with the welding instructor

-cleaning up the welding booth at the end of the day

-the average of real welding time a day is approximately 30%

Sequence of a training day in a welding booth

trai

ning

-cyc

le


Explanation of Machine Hour Rate

Machine hour rate: - is a parameter of management accounting

- includes all the costs while using a machine

- that parameter does not includes labor costs


Machine Hour Rate (1)

Calculation of machine hour rates

GSI SLV Welding Trainer Welding boothAquisition costs 16650,-€

(incl. additional PC)9950,-€ (incl. fume

extraction, welding table, external Equipment)

„Fixed expenses“ per week per week

depreciation 61,67€ 23.03€

interest (6%) 9,25€ 5,53€

maintainance ( repair & service)

9,26€ 18,52€

rental fee 3,11€ 5,19€


Machine Hour Rate (2)

Calculation of machine hour rateGSI SLV Welding Trainer Welding booth

Aquisition costs 16650,-€ (incl. additional PC)

9950,-€ (incl. fume extraction, welding table,

external Equipment)„Variable costs“ per week per week

power 0,86€ 2,58€consumption of shielding gas

15,18€ 25,56€

consumption of cutting gas (C2H2, O2)

/ 5,95€

repair/service 23,15 9,26€

water for cooling / 0,08€base material (plates) 1,84€ 53,30€

operating materials 2,20€ 6,65€

machine hour rate 4,22€ 5,19€


Explanation of cost comparison method

Cost comparison method: - is an economical parameter

- all costs that result in the training process

- that parameter also includes labor costs


Expenses

What do the different expenses include?

Fixed expenses: - depreciation- interest- maintainance- rental fees- labor costs of an Instructor (50% less for the Welding Trainer )

Variable expenses: - Material consumption - consumption of operation materials (shielding

and cutting gas, water)- consumables - Power- repair and service


Cost comparison method

Cost comparison of different economical situations in the workshop

Welding Trainer

Weld. booth Welding Trainer

Weld. booth

Aquisition costs

16650,-€ 9950,-€ 16650,-€ 9950,-€

Fixed expenses

9265,-€ 12057,-€ 9265,-€ 12057,-€

Variable costs

701,-€ 1674,-€ 1867,-€ 4465,-€

Fixed & variable c.

9966,-€ 13731,-€ 11132,-€ 16522,-€

Difference per year.

3765,-€ 5390,-€

Utilised capacity 30% Utilised capacity 80%

Amortisation will achieved after 1,8 and 1,2 years


Health and safety

Comparison in terms of health and safety.

Welding booth GSI SLV Schweißtrainer

100% 60%

100% 65%

100% 75%

100% 30%

100% 15%

Harmful impacts are lowered on about 50%!

ca.50%


Practical relevance

Comparison in terms of practical relevance.

Welding booth GSI SLV Schweißtrainer

25% 0%

25% 10%

25% 25%

25% 10%

100% 45%

There will be reached a practical relevance of very good 45%!(Not regarded the real torch, using of helmet, gas, power source…)


Students-Evaluation

What do the students say after the training session at GSI SLV Schweißtrainer?

- …combination of practical training and computer equipment is very interesting….

- …we had a lot of fun..- …adjustment of errors during the training session was great….- … the scoring create a competition in the group ….- … I was especially impressed by e-Learning software .…

- … after achieving good scores at a high level, the motivation goes down….

- ….anytime everybody wants to weld in a real enviroment….


Summary

Summary and outlook

1. The machine hour rate of GSI SLV Schweißtrainer is about 20% less than that of the welding booth.

2. An Amortisation regarding to the higher price will achieved after 1.2 or 1.8 years. That depends on the utilised capacity of the workshop.

3. The health risk can be reduced to 50%.4. The practical relevance of the GSI SLV Welding Trainer will be

assessed at 45%.5. Adjustment of errors immediately during welding is very special.6. As a result of the scoring system a competition is developing between

the students. That increases the motivation.7. The students can get theoretical knowledge in parallel to practical

training.8. After achieving a high scoring at the final level the motivation goes

down.9. The recommended training time should not be longer than 1 week.


End

Thank you for your attention!

schweißtechnische lehr- und versuchsanstalt halle gmbh april 15 analyses of the cost efficiency...

Documents

welding table

welding trial

welding instructor duration

training day

average of real welding

day sequence

training systemintroduction

training program curriculum