unlock your potential - hobart brothers · unlock your potential solutions for continuous...
TRANSCRIPT
U n l o c k Yo u r P o t e n t i a ls o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
O U R G O A L :
T O U N C O V E R C O N T I N U O U S I M P R O V E M E N T P O T E N T I A L
T H R O U G H I D E N T I F I C A T I O N O F K E Y V A L U E A N D
N O N - V A L U E A C T I V I T I E S I N T H E F A B R I C A T I O N P R O C E S S .
M E A S U R E A B L E B E N E F I T S T O T H E C U S T O M E R :
I N C R E A S E D O U T P U T
O V E R A L L W E L D I N G C O S T R E D U C T I O N S
I M P R O V E D Q U A L I T Y
STEP 1:Discovery
STEP 2:Identify
Key Drivers
STEP 3:Documentation
Review & Proposal
STEP 4:Implementation
STEP 5:Monitoring &Verification
In-depth analysis by industry experts shows that labor is the major cost driver in most fabrication operations. Our goal at Hobart Brothers is to help you reduce labor for non-value-added activities—those tasks that don’t contribute to your overall productivity or bottom line. And we can lower your overall costs along the way.
How? With our exclusive Improvement Potential (IP) Methodology that looks at:
P R E - W E L D A C T I V I T I E S
W E L D A C T I V I T I E S
P O S T - W E L D A C T I V I T I E S
This approach helps you identify the potential for productivity improvements and cost savings in your fabrication operation, specifically where most non-value-added labor occurs: in the pre- and post-weld areas.
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
Consider the cost breakdown of a typical welding process:
Labor 85%
Gas 3%Power 2%
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
In many welding operations, a large percentage of the labor (as shown here) is non-value-added. It is used for costly activities like grinding, sandblasting or chipping that may not be necessary—and that could be lowering your potential for greater productivity.
We can help you determine if these activities exist in your welding operation.
Electrode 10%
“The technical support we received throughout
the conversion process can’t be touched. Our
Hobart representative showed how we could
improve our weld quality and productivity with
a new wire, plus reduce our clean up. These
benefits were the real selling point.”
MILT SIESKY, SENIOR INDUSTRIAL ENGINEER/WELDING, JLG
MCCONNELLSBURG, PA
Hobart Brothers’ Improvement Potential (IP) Methodology focuses first and foremost on developing a long-term, mutually beneficial partnership between our company and yours. It’s an approach we believe in and it begins by listening to your needs.
We first engage in a sharing discussion and a brief walk though your facility. Our objective is to identify areas of your welding operation that can be enhanced. We also look for non-value-added activities that may be hindering your productivity and/or unnecessarily increasing your costs.
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
Step 1: Discovery
“The Hobart team helped us get the right
parameters for our metal-cored wire and
provided more technical support than I’ve gotten
from any other company. It was phenomenal.
Plus, with the metal-cored wire, we’ve gotten
nearly a 30 percent increase in productivity
with our robots.”
CARL BAATZ, PLANT MANGER, SQUARE DEAL MACHINING
MARATHON, NY
Hobart Brothers has highly trained experts that work directly on the shop floor to identify key problems that you and your team can then prioritize. Depending on your particular welding operation, we can even provide robotic or process support to help in the assessment.
Some of the areas of the welding operation we examine during the IP Methodology process are:
Step 2: Identify Key Drivers
PartMovement/
loading
Fill-up & Tack
SandBlasting
Grinding/Blending
Blending
Anti-spatter
Application
Pre-Cambering
PartMovement/
Indexing
Grind/Blend
AirMovement
Fill-up & Tack
Arc-onTime
(Welding)
Anti-spatter
Application
SandBlasting
PartCleaning/ Rinsing
PartMovement/Unloading
Grinding/Blending
Chipping/Scraping
WeldRepairReject
Post-weldActivities
WeldActivities
Pre-weldActivities
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
“Our IP (Improvement Potential) Methodology
helps us help our customers. It’s exciting to
provide the tools they need to uncover
productivity increases and cost reductions
in their welding process.”
DOUG KREBS, HOBART BROTHERS
BUSINESS UNIT MANAGER
Step 3: Documentation Review & Proposal
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
After compiling data into a final report, Hobart Brothers’ experts review their findings with you in an open forum. Depending on the data collected, the report may include suggestions for alternative methods, materials and/or processes, or we may conclude that additional information or verification is necessary.
It’s then your decision whether to implement some, all or none of the suggestions we’ve provided.
“It’s rewarding to know that we can analyze a
customer’s fabrication process and then offer
them a real solution to increase their
productivity. It’s even better to see what a
difference it can make on their bottom line.”
PETER CORTINA, HOBART BROTHERS
BUSINESS DEVELOPMENT MANAGER
Step 4: Implementation
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
We recognize that your time is valuable. Should you proceed with the improvement proposal Hobart Brothers provides, we will be with you every step of the way. Our goal is to provide seamless and prudent transitions and also to offer the resources you need to be successful. These include:
~ W E L D E R T R A I N I N G
~ C L A S S R O O M T R A I N I N G
~ M A C H I N E S E T - U P
~ R O B O T I C S U P P O R T
~ P A R T R U N - O F F S
~ M E T A L L U R G I C A L A N A L Y S I S
~ E T C H E D C R O S S - S E C T I O N S
“There are so many factors that affect a
customer’s total weld cost. That’s why our IP
Methodology analyses the entire fabrication
process, not just the welding process. It
especially let’s us look at ways to eliminate
pre- and post-weld activities and lower our
customer’s overall costs in those areas.”
RICK CONRAD, HOBART BROTHERS
BUSINESS DEVELOPMENT MANAGER
Step 5: Monitoring & Verification
‘Hobart Brothers’ support doesn’t end after implementing your improvement proposal. Our representatives follow-up regularly to monitor all areas of your operation, including your pre- and post-weld areas. We want to verify that your welding process is reaching it’s productivity and cost-savings potential.’
s o l u t i o n s f o r c o n t i n u o u s i m p r o v e m e n t
Hobart B
rothers
Key Account M
anagement (KAM)
Summary Report
ITW Welding Toolbox
Confidential
Welding Process Analyser
1/21/10
Customer
Weld Metal Deposition Summary
96 Inch Loader Bucket : Case Example
0.059 in2
Current Procedure
New Procedure
Note : Numbers shown on this report are estimates only, any changes will modify the results
Procedure / Process Total Cost $158.51
ITW Hobart Brothers of Canada
Additional Variable Expense(s) [$]1.00
Total Gas / Flux [$]Power [$]
0.96
Welding Labor [$] 120.16Total Electrode [$]25.14
Procedure Cost
Pre & Post Weld Labor [$]11.25
Power Consumed [kWh]12.05
Electrode Consumed [lbs]15.05Gas / Flux Consumed [ft3]41.65
Weld Consumable Usage Summary
Heat Input Summary
Heat Input [kJ/in]37.1
Cycle Time [min] 105.13
Total Welding Time [min]96.13
Cycle Time
Pre-weld Time [min]Post-weld Time [min]
9.00
TotalWeld Metal Required by Weld Joint [lbs]
14.60Overweld (Underweld)0.0%
Weld Metal Deposited [lbs]14.60
161.3621.351.681.343.00
$266.23
191.09
51.7
16.0555.9416.78
77.50
Fillet - Flat73 ft
Weld Consumable Usage Summary
Total Welding Time [min]
Weld Metal Deposited [lbs]
Overweld (Underweld)
Weld Metal Required by Weld Joint [lbs]
Cross Section Area (CSA)
Joint Type
Weld Procedure Summary
NameTitle
CWS Industries
604-888-9008
Company Name
Cycle Time [min]
Address
TelephoneFax
Postal Code / Zip Code
19490 - 92nd Ave.
V4N 4G7
Procedure Cost
Heat Input [kJ/in]
Post-weld Time [min]
Pre-weld Time [min]
Power Consumed [kWh]
Electrode Consumed [lbs]
Province / State
Procedure / Process Total Cost
Total Electrode [$]Total Gas / Flux [$]Additional Variable Expense(s) [$]
Power [$]
Welding Labor [$]
Pre & Post Weld Labor [$]
Cycle Time
Gas / Flux Consumed [ft3]
Total length of weld joint
Total
Heat Input Summary
14.6114.600.0%
17.00
129.09
45.00
Joint Information
SurreyBritish Columbia
City
ITW Welding Toolbox
Confidential
Welding Process Analyser
1/21/10
General Information
Welding Procedure Detail
Note : Numbers shown on this report are estimates only, any changes will modify the results
ITW Hobart Brothers of Canada
1.33
17.00chip and clean spatter
Description
11.48
10.44
45.00
0.03
Description remove mill scale from blade / apply anti spatter
Power Supply Efficiency
6.79
300
65
91
40
1
0.75
Process 1
Description
3.00
anti spatter spray and grinding wheels etc.
1
Post-weld Time [min]Pre-weld Time [min]
Gas / Flux Cost [$/ft3 or $/lbs]Electrode Cost [$/lbs]
Additional Information
Additional Variable Costs [$]
Description
Electrode Classification
Power RateTotal length of weld joint
Labor & Overhead Rate
AWS E70S-6
New Procedure
Total # of Weld Passes
73 ft
Welding Procedure Detail Report
PQR # / Procedure #
96 Inch Loader Bucket
Case Example
0.08 $/kWh
Current Procedure
75 $/hr
75 %
Total # of Weld Passes
Esab S-6 Solid Wire
Process 1
Consumable Cost Information
Wire Feed Speed [in/min]
Number of Weld Passes
Electrode Brand Name
Welding Process
Actual Deposition Rate [lbs/hr]
Procedure Variables Information 1
[G] Ar / 8-10% CO2
Electrode Diameter [in]
Theoretical Deposition Rate [lbs/hr]
Deposition Efficiency [%]
Welding Travel Speed [in/min]
Type of Gas / Flux
Welding Current [amps]
Welding Voltage [volts]
Electrode Stick-out [in]
[00] GMAW (Man)
0.045
30.0
425
Operator Factor [%]
Gas Flow or Flux Ratio [cfh or flux/wire]
Procedure Variables Information
Number of Weld Passes1
CSA E4801C-6-CH
65
Electrode Classification
Electrode Stick-out [in]
Welding Process[30] MCAW (Man)
Type of Gas / Flux
[3] Corex 6XC (Canada)
Gas / Flux Cost [$/ft3 or $/lbs]
Theoretical Deposition Rate [lbs/hr]
Actual Deposition Rate [lbs/hr]
Electrode Cost [$/lbs]
Welding Current [amps]
Operator Factor [%]
Gas Flow or Flux Ratio [cfh or flux/wire]
Electrode Brand Name
Deposition Efficiency [%]
Wire Feed Speed [in/min]Electrode Diameter [in]
Welding Voltage [volts]
1.67
Welding Travel Speed [in/min]14.02
14.46
3101.00
1.00
9.11
Consumable Cost Information
Additional Variable Costs [$]
Additional Information
Pre-weld Time [min]
Post-weld Time [min]9.00
[G] Ar / 8-10% CO2
300
97
0.062
28.0
40
Description
Description
Description less grinding disk/wire wheel usageno grinding on blade requirred
less spatter to clean
SubstantialSavings!
17.0045.00
3.00
9.001.00
$266.23
$158.51
International Headquarters Phone: 937-332-5188 FAX: 937-332-5064
Regional Office - Canada Canadian Welding Products Group Phone: (519)-537-6291 Fax: (519)-421-0480
Regional Office - Middle East Phone: +971-4299-6621 FAX: +971-4299-6681 E-mail: [email protected]
Regional Office - India Phone: +91-222520-7388 FAX: +91-222520-7389 E-mail: [email protected]
Regional Office - Asia Phone: 65-6552-1223 FAX: 65-6552-1929 E-mail: [email protected]
Beijing Miller Electric Phone: +86-10-8739-7900 FAX: +86-10-8739-7600 E-mail: [email protected]
Regional Office - Brazil Phone: +55-11-5514-3366 FAX: +55-11-5891-7679 E-mail: [email protected] Web site: www.itwsoldagem.com.br
Regional Office - France Phone: +33-1-6004-1166 FAX : +33-1-6004-8860 E-mail: [email protected] Web site: www.miller-france.com
Regional Office - Italy Phone: +39-02-9829-0218 FAX : +39-02-9828-1552 E-mail: [email protected]
Regional Office - Netherlands Phone: +311-866-41456 FAX : +311-866-49020 E-mail: [email protected] Web site: www.itw-welding.com
Regional Office - Mexico Phone: +52-55-5366-7370 FAX : +52-55-5366-7376 E-mail: [email protected] Web site: www.itwweldingmexico.com
Welding Industries of Australia Phone: +61-1300-300-884 FAX: +61-8-827-66327 E-mail: [email protected] Web site: www.welding.com.au
Weldwell New Zealand Phone: +64-6-834-1600 FAX: +64-6-835-4568 E-mail: [email protected] Web site: www.weldwell.co.nz
Regional Office - Northern Europe Phone: 46-031-726-4600 FAX: 46-031-726-4700 E-mail: [email protected] Web site: www.elga.se
Regional Office - Russia Phone: +7-812-961-5481 E-mail: [email protected] Web site: www.itw-welding.ru
To locate your nearest Hobart distributor call 1-937-332-4000 or 1-937-332-5188 or visit our Web site www.hobartbrothers.com
Headquarters Hobart Brothers Company 101 Trade Square East Troy, OH 45373 Phone: 937-332-4000 Fax: 937-332-5700
Hobart Distributors
Regional Office - Spain Phone: 34-963935398 FAX: 34-963629516 E-mail: [email protected]
Regional Office - Africa Phone: +44-7770562799 FAX: +44-1204-473039 E-mail: [email protected] Web site: www.itw-welding.co.uk
Regional Office for:
Colombia, Venezuela, Trinidad & Tobago, Panama Phone: 920-968-7508 FAX: 920-735-4125 E-mail: [email protected]
Ecuador, Peru, Bolivia, Chile, Argentina, Uruguay, Paraguay Phone: 920-968-7508 E-mail: [email protected]
Guatemala, El Salvador, Honduras, Nicaragua, Costa Rica, Belize Phone: 525553667370 FAX: 525553667388 E-mail: [email protected]
Bahamas, Barbados, Dominican Republic, Jamaica, Puerto Rico, Virgin Islands Phone: 937-332-5188 FAX: 937-332-5064 E-mail: [email protected]
Manufacturers:
Tien Tai Electrode Co., LTD Phone: 886-6-2663721 Fax: 886-6-2664301 Web site: www.tientai.com
Tien Tai Electrode (Kun Shan) Co.
Phone: 86-51257446669 FAX: 86-51257448416 E-mail [email protected] Web site: www.tientai.com
Elga AB Phone: +46-31-726-46 00 FAX: +46-31-726-47-00 Web site: www.elgawelding.com
Hobart Brothers Company101 Trade Square EastTroy, OH 45373www.hobartbrothers.com