Welding Intervention : 4 P – Product, Process, Plant and People Towards Zero Defect in Welding

Background

When asked ‘How do you resolve the welding related issues on our shop floor?’ to any practicing Welding Engineer, the answer, most likely, you will get is ‘ By trial and error! ‘. It ends up in more trials and more errors, and the issues getting ‘somehow’ sorted out – a symptomatic relief rather than a lasting cure!

In Nashik we have more than 1400 MSMEs dealing with Welding related issues. We as IFC made field visits to some of these MSMEs with a welding expert. We selected industries from different segments to understand the Pain Area or Process gaps on the shop floor. We found some key challenges that prevent MSMEs from Zero Defect in Welding.

  • Most of the GMAW process users were simply unaware of dynamics of the heat and metal transfer to weld joints
  • Majority were doing excessive welding believing it will give strength to the joint.
  • Welding practices adopted were based on inputs from equipment seller’s- representatives, and migratory welder-workers.

Welding intervention was therefore planed for application of correct welding techniques at shop level and education of top management/ decision makers on achieving qualitative productivity and cost efficiency in the long run through adopting  best practices of welding technologies

Approach

The intervention process  is not a one time  activity which is complete by attending a workshop. It’s a circle which connects Product–Process–Plant and People. We approach this in two parts Product- Process by classroom training and Plant – People by field training.  

  • We had expert visit to MSMEs and capture parameters like production line, welding process used, recent issues in quality or causes for rejection.
  • Based on this parameters, workshop content is designed where Industry can relate scope for intervention in their process for welding.
  • In a 3-hour classroom training session, the welding expert covered:
    • Behaviour of Engineering Materials being used during welding
    • Right approach to control of process
    • Checklist, Do & and Don’ts while doing the job work
  • Metallurgical aspects, MIG, SMAW welding techniques through videos.


Direct Inputs on Field Visits

 On field we addressed pain area directly affecting welding cost and quality.

  • Improper settings and conditions of the GMAW Torch delivery point
  • Improper welding technique used by welders: holding the gun with only one hand due to use of hand-shield instead of helmet.
  • excessive gas flow rates: 16 to 22 ltr instead of 8 to 10 ltr specified.
  • Excessively high currents due to points 1 and 3 above: using 150 to 220 amp welding current instead of 70 to 90 amp range recommended; resulting in heavy spatter
  • Absence, bad condition and wrong angle of gas Flow Meters

Industry specific points are mentioned along with photographs in a detailed report and are being monitored over the next 3 months for expected results discussed with MSMEs.

Testimonials

“The Welding Technologies Workshop organised by NIMA-GIZ IFC along with plant visits and Practical Solutions proved to be very beneficial to participant industries. This result oriented approach to offer technological solutions to SMEs will really help entrepreneurs of Nashik.”

Deepak Dharkar, Founder Managing Director, R&D Therm (I) Pvt Ltd

“The welding Workshop has changed the way we look at welding. We used to put the part in water after welding but now we don’t do it as it causes martensite formation. We are saving CO2 gas as we got to know that our flowmeter was placed in wrong way. Our spatter has redused substantially after expert visit. Our welding operator is taking it seriously and trying to improve his welding skills.”

Rushikesh Umrajikar, Varad Enterprises