FINAL_TOTAL_WELDING_MANAGEMENTFeb2022.pptx

This presentation covers the total welding management concepts and few cast studies to illustrate the improvements in quality and productivity made in welding operation.
THis ppt is made based BARCkOFF book on Total welding management and case studies included from experience in the industries
Basic assumptions made by the author are>
1. Welders are eager to learn and change, be held accountable
2. The welding process can be controlled and measured.
3. Welder productivity and quality can be improved with less welder effort
4. Total Welding management represents a management and cultural change in many companies.This change requires support to welders by all functions from design, manufacturing engg. through manufacturing operation, quality assurance.
5.It is a process focusses on the entire organisation in supporting the welder and provides a plan with closed loop feed back to detect and correct deviations from the plan.
Based on working with a fabrication unit in a public sectors few case studies are chosen to demonstrate the concepts.

1. 6/5/2024

2. Dr. Asokkumar K. Professor/ Metallurgical Engineering PSG college of Technology,Coimbatore Former AGM/Welding Technology Centre , BHEL,Trichy Contact : [email protected] About the Speaker 6/5/2024

3. Mr. M.P. Jain Former ED, EIL Member, NGC – IWS Contact : [email protected] About the Moderator 6/5/2024

4. Quality and Productivity Improvement. 6/5/2024 What is Total Welding Management? TWM is a system focused on

5. Why do companies want to implement Total Welding Management System? 6/5/2024

6. The surveys have showed some of the following results: Improper Weld Quality Standards Improper Welding Procedures Poor or lack of work methods Non Value added work – poorly prepared parts, excess welds 6/5/2024

7. General Conditions on the Shop Floor Lack of ability to interpret welding symbols properly Wasted time waiting for parts or instructions Lack of shop floor documentation Inconsistent Work Standards 6/5/2024

8. Weld Size Control Control of the Essential Welding Variables Minimize Wasted Time Using Work Center Control (flow of consumables) Consistency of Standards Training of key personnel to maintain the program Monitoring and Auditing The Productivity Improvement Will Focus On: 6/5/2024

9. Surveys have shown that with Total Welding Management System Welder work effort 6/5/2024 Productivity

10. Savings $15, 000 – $20,000 Per welder per year 6/5/2024 Welder work effort

11. TWM Key Features 6/5/2024

12. Total Welding Management It is a management system that transforms a company’s culture into an Inverted Triangle organization that supports and serves the welder at all levels and within all functions, resulting in better attitude, morale and self-esteem 6/5/2024

13. This is a 3 phased process of evaluation, planning & improving all welding-related activities in a company. Total Welding Management System 6/5/2024

14. Application Thin sheet & all position welding capability Globular transfer Short circuit transfer Spray transfer Medium voltage & current Low voltage & current High voltage & current Applications Down hand position welding Sheet thickness > 2 mm METAL TRANSFER IN GMAW Welding is science no more art 6/5/2024

15. 6/5/2024 Principle of Total Welding Management

16. Combines the skill, science and technology of welding with tested and proven management principle and concepts . 6/5/2024 Principles of Total Welding Management

17. 6/5/2024 Most Employees Want to do a Good Job. Most problems with production and quality can be traced to lack of training or poor welder support from critical functions in the company . Principles of Total Welding Management

18. Training in TWM application is an important part of the program 6/5/2024 Principles of Total Welding Management

19. Hands – On Leadership. Support functions taking responsibility and accountability for providing welders with what they need to do a good job. Providing bulk pack wire instead of spool wire for MIG (automatic) although bulk pack costs 20 % more than spool wire The additional cost can be more than offset due to reduced rework, more weld on-time and better quality 6/5/2024 Principles of Total Welding Management

20. 6/5/2024 Principles of Total Welding Management

21. 6/5/2024 Principles of Total Welding Management

22. Assign responsibility for results to those doing the work. Welders manage their work area and are responsible for their: - Quality - Productivity - Throughput 6/5/2024 Principle of Total Welding Management

23. Welders will inspect and guarantee their work rather than waiting for inspection dept. 6/5/2024 Principle of Total Welding Management

24. Auditing, monitoring, measurement and feedback are an important part of the program 6/5/2024 Principle of Total Welding Management

25. 36% 44% 56% 77% % Increase in Amount of Weld Metal Weld Size Increase 3 / 8 5 / 1 6 1 / 4 3 / 1 6 3 / 8 5 / 1 6 1 / 4 7 / 1 6 6/5/2024 Cost of Overwelding

26. 6/5/2024 Cost of Overwelding

27. WFS V oltage T ravel CTT W D Polarity Position T r a vel Transverse 6/5/2024 Cost of the 8 Essential Welding Variables

28. 6/5/2024 Effect of Transverse Angle

29. 6/5/2024 Variables Out of Control

30. Training in Application of the Program – Welding Supervisors 6/5/2024

31. Why is a TWM Welding Supervisor Important to Your Company? A welding supervisor, more than individual can have the greatest impact on the productivity and quality of your welding operations 6/5/2024

32. Assign tasks to personnel under their direction Expeditors Chasing parts Pushers to get out production Liaison with engineering to determine what they want Front end loading of production line and personnel but sometimes little interaction after that 6/5/2024 What are Supervisors Actually Doing?

33. Technically well versed in welding processes Major support for department personnel (tools, materials, procedures, etc.) Responsible for all in-process operations Accountable for the quality and productivity of the department. Able to identify operational inefficiencies and implement solutions 6/5/2024 What Should Supervisors Be?

34. 6/5/2024 Under any System the Supervisor has the Important Role of Identifying and Controlling What Workers Actually Do

35. Training of Key Personnel to Maintain the Program 6/5/2024

36. 6/5/2024 Training IWT’s for TWM Companies

37. 6/5/2024 IWT’s Evaluating New Welder Performance Using the Eight (8) Essential Variables

38. 6/5/2024 Demonstration of the Essential Welding Variables

39. 6/5/2024 Presentation of Lecture Sessions

40. 6/5/2024 Evaluating Welder Performance on the Shop Floor and Training for Improvements

41. 6/5/2024 WPS Development

42. Work Centre Control Planning 6/5/2024

43. Controlling inputs for consistent quality and productivity output 6/5/2024

44. 6/5/2024 Total Welding Management: Closed Loop Feedback System

45. Do Reduce Weld Metal Volume Do Reduce Arc Time Per Weldment Do Reduce Rejects, Rework and Scrap Do Reduce Work Effort Do Reduce Motion and Delay Time 6/5/2024 The Five Do’s (Goals)

46. Volume (weight) of weld metal should be consistent with design and application requirements Designers should specify weld sizes based on loads and service requirements Welders should not deposit welds larger than required by the design specifications (as indicated by welding symbols on shop drawings) 1. Do Reduce Weld Volume 6/5/2024

47. Change of Edge Preparation : LINES & LINKS Shop Optimisation Challenges faced Modification Done Change of E.P style from COLLABORATOR Style to conventional 'P' Style for Pipe Thickness is less than and equal to 70 mm 70% of excess weld metal is deposited, in turn increasing the consumption of the welding consumables and Cycle Time for Welding High included angle Style is changed into low included angle 'P' Style. STYLE A Optimum ‘P’ STYLE WELD VOLUME:503596 CUBIC MM ( 70%INCREASE ) WELD VOLUME:379761 CUBIC MM Auto butt joint of Collaborator style ends requires TWICE the cycle time that required for P style . 6/5/2024

48. Arc time is minimized by maximizing travel speeds This goal centers on deposition rates of the welding process used Optimizing wire feed speeds/amperages is the key (Knowledge & Choice of welding process is the key) 2. Do Reduce Arc Time per Weldment 6/5/2024

49. Substitution of SMAW to FCAW to reduce arcing time ( supercritical boiler components) Collector Vessel SEPARATOR VESSEL NOZZLE Macrosection at 18 0 deg Macrosection at 0 deg P91 F22 6/5/2024

50. Eliminate or correct any situation that result in unacceptable welds Establish definition of quality through a Workmanship Performance Standard Establish a prevention system as opposed to an inspection system - “Build it right the first time” The goal is “Zero Defects” 6/5/2024 2. Do R educe Rejects, Rework and Scrap

51. Si/ Mn ratio Weldline 6/5/2024 Reduction of rejection in the expander after FLASH welding ( 15 % to 0%)

52. Reduce the degree of difficulty, fatigue or hazard associated with welding Focus on methods, work habits, equipment, tooling, design etc. 6/5/2024 4 . Do R educe Work Effort

53. By making suitable modifications in SAW-Auto welding machine, all butt joints of Headers (Even with SPOOL Pipe in Tee branch end) are Auto welded avoiding 10 manual joints. Shop hydro test @ 475 Kg/cm2 established. 6/5/2024 Before After Work Effort Reduction 6 G Cirseam 1 G cirseam

54. Poor Access Increases Work Effort 6/5/2024

55. Reduce wasted time (unnecessary activities or effort) Reduce excess motion or repeat time Reduce delay time (waiting time) Focus on work center planning and control 6/5/2024 4 . Do R educe Motion & Delay Time Work Effort

56. A joint is introduced to facilitate down hand (1G) welding for Plug Type End cover. SAW- Auto welding machine developed for Plug type end cover welding instead of manual arc welding to reduce cycle time. Fit up of PEC Manual welding of PEC SAW Rotating table for SAW 6/5/2024 Plug Type End Cover Welding Work movement simplied

57. These are the factors welders have control over 6/5/2024

58. 6/5/2024

59. Important Documents: Engineering Standards Workmanship Standards Welding Procedures Method Procedures Work Instructions Welder Performance Test 6/5/2024 Principles of Total Welding Management

60. Five Key Results are Applied to Each of the Four Functions 6/5/2024 Principles of Total Welding Management

61. The Five Key Results Areas of Each Function 6/5/2024

62. 6/5/2024

63. 6/5/2024 TWM’s Structured Approach to Welding Management Can Optimize:

64. The AWS along with the National Shipbuilding Research Program released a report in 2003 on the advantages TWM and training welding supervisors Results from Training at One Shipyard TENTITAIVE SAVINGS (Summarized by Broad Category) Prioritized Goals Potential Savings Per Welder 1. Reduce weld metal volume $3,319 2. Reduce arc time per weldment $4,281 3. Reduce rework, scrap and rejects $3,244 4. Reduce work effort 5. Reduce motion and delay time (included with #4)$6,200 Total Estimated Potential Savings $17,044 per welder 6/5/2024

65. IMPROVEMENTS IN PANEL WELDING USING TWM: Case Study 6/5/2024

66. 6/5/2024 Improvements In Panel Welding REWORK IN PANEL FORMATION TO BE REDUCED 20 torch welding machine Earlier Cycle time for rework was about 4 days Survey of defect level in 5 m/ cs ( 2 nos PEMA& 3 nos 20 torch) revealed that 20 torch machine defect level is about 6 % SKIP DEFECT

67. 6/5/2024 CAUSE AND EFFECT DIAGRAM FOR WELDING DEFECTS IN 20 TORCH panel welding MACHINE Men Material Machine Method s Torch angle Variation in Pitch of tube guide rollers due to Improper shim Surface preparation Defects Operator skill and knowledge Use of multiple shims instead of single shim Continuous observation under heat Manipulation of sequence Cleaning of nozzle for spatter Periodic checking of gas flow and feed rate Electrode storage/ Coating Proper alignment of tube and fin Metal transfer Stick-out Gas mixture Periodic maintenance Calibration of digital meters Periodic change of contact tip and nozzle Current/ Voltage/ Travel Speed Electrode feed rate/ Gas flow Identification of measures

68. Need for defect free panel welding to meet customer (NTPC, etc) demand. Exposure on MIG Welding, defects and remedies and Panel welding machine operation. Pre-test and post-test to quantify operator knowledge level .( Average score 10 in pretest is raised to 18 in post test ) WELDING OPERATOR TRAINING Sample Questions 6/5/2024

69. MECHANISED WELDING SYSTEM FOR IRREGULAR SHAPED TUBES Improved productivity (300%) No need for skilled welder to perform the weld and could be deployed for other jobs. Improved quality level. Reduced possibilities of weld discontinuities. 6/5/2024

70. DEVELOPMENT OF NEW WELDING PROCEDURE FOR JOINING U PIECE WITH STRAIGHT TUBE 6/5/2024

71. TIG” WITHOUT FLUX ATIG “WITH FLUX” 6/5/2024

72. WELDING AUTOMATION Vertical Panel Welding 6/5/2024

73. WELDING AUTOMATION Thin walled pipe welding with low cost automation 6/5/2024

74. 4. Tube leveling arrangement Previous method Improved method 1. Improved method of viewing overhead position weld 3. Improved method for mounting spools for overhead torch 2. Gas flow sensor provided. Implementation of measures 6/5/2024

75. Pendent given to operate all group torches at a time Pendent given for reverse mode operation 5. Machine control improvement to reduce skip Implementation of measures 6/5/2024

76. These improvements could reduce the rework level from 7% to less than 1%. Recently formed some panels rework data is shown below:  panel details Porosity Skip Fin play Lack of Fillet Weld Offline Under Cut Metal Drop Total Rework % WO: 1718-11-967, DU:003 Cold Side 400 4400  2800 3650 1.07 Hot Side 10000  0  0 1550  0 11550 WO:1718-11-967, DU: 004 Cold Side 2400 3850  0  0 2650   8900 0.9 Hot Side 1950 300      750 3000 WO:1712-11-767, DU: 006 Cold Side 1000 1160     2300     4460 0.7 Hot Side 2440     3450   800 6690 WO: 1718-06-741, DU: 10 Cold Side   2530     500     3030   0.6 Hot Side   1620     4600   200 6420 WO: 1718-06-741, DU: 12 Cold Side 100 3360     100   100 3560   0.7 Hot Side 1300 3400     1900   100 5700   Total 16750 19060     21450   1200 56950   6/5/2024

77. 6. Exhaust fan mounted ventilation of welding fumes and improve operator comfort 7. Pendant provided to operate walking beam Men ( feel comfort) Implementation of measures 6/5/2024

78. “The search for a quick fix is a universal human failing” Peter Drucker 6/5/2024 How Long Will the Process Take?

79. 6/5/2024 QUESTIONS?

80. Thank You! 6/5/2024

81. 6/5/2024 Thanks to Jr Barckhoff for the concept and AWS for bringing out a book