WELDING PRODUCTIVITY

& ECONOMY

WELDING ECONOMY & PRODUCTIVITY

Productivity is a measure of Efficiency Productivity = Output / Input Productivity can be improved by improving the capacity utilization or by elimination of waste. Productivity is an attitude of mind. Waste is any unnecessary input or any undesirable output from the system.

Output
No* 0f Parts / components / units produced per shift

Weld Metal Deposited per unit time

Weld length completed per unit time
Output Input
Weld Metal Deposited / weld Length Completed Consumables, Energy, Welder hrs, Accessories

* Here number refers to defect free / acceptable parts

that meets the specified quality requirements

Productivity
Overall Plant/Shop Productivity Welding Productivity Labour Productivity

Welding Productivity is often affected by Productivity of other allied processes

Productivity is directly dependent on welding time and time taken for allied operations

Cost

DISTRIBUTION OF WELDING COST

70% 60% 50% 40% 30%

Preheating Welding Dressing PWHT

Preparation
Assembly

20%
10%

Inspection

Welding Time standards

WORK MEASUREMENT TECHNIQUES

Time Study Work sampling Analytical Estimation

Synthesis from Standard Data

METHOD STUDY SHOULD PRECEDE WORK MEASUREMENT

Welding Time standards

STANDARD TIME
Standard Time for a welding operation is the amount of time that the qualified, properly trained and experienced welder should be take to perform a specific welding operation under specified conditions under normal performance.
OBSERVED TIME * RATING FACTOR = NORMAL TIME NORMAL TIME + ALLOWANCES = STANDARD TIME FATIGE ALLOWANCE, PERSONAL NEEDS AND DELAYS. STANDARD TIME WILL BE CALCULATED BY BREAK DOWN OF VARIOUS ELEMENTS IN WELDING.

Welding Time standards

ELEMENTS OF WELDING OPERATION

ARCING Note down ampere, dia and length of electrodes used.
CLEANING - Chisel / Wire Brush / Pneumatic chipper, No. of layers used MANIPULATION DURING WELDING Change electrode, adjust current, getting electrodes, move accessories, Remove and put on helmet, gloves, apron etc. MANIPULATION OF THE JOB - Turning, lifting, clamping, declamping etc of the job.

Welding Time standards

Example Calculation of Standard Time

Sl. No. Description of the element
Preparationon Time

Welding ManipulTime ation Time

01. 02. 03.

Collect documents Study the Drawing Connect the plug and disconnect later

2.0 1.5

0.2

04.
05.

Switch on and Stop later

Adjust Current

0.3
0.2

Welding Time standards

Example Calculation of Standard Time

06.
07. 08. 09. 10.

Clean Work Place

Fill up the Job Card Handover completed Job Card Call Crane Tie and loosen the piece

1.5
2.0 2.0 3.0 1.25 0.9 0.15 14.00 0.10

11.
12. 13. 14.

Bring the job from a distance of 20 Metres

Clamp the earthing cable Weld 2Metres with basic coated electrode Complete Weld Ends

15.

Move to side

0.60

Welding Time standards

Example Calculation of Standard Time

16. 17. Call Crane Rig and Untie

3.0 1.25 1.00 14.0 0.10

18.
19. 20.

Change through 180 degrees

Weld Next side 2Metre Complete the weld

21.
22. 23.

Stamp welders Number

Call Crane Rig and Untie

0.10 3.00
1.25 0.90 9.70 28.20 16.40

24.

Take the piece away for 20 Metre distance

Total time in mins.

Welding Time standards

ANALITICAL CALCULATION

In this method, arcing time, welding time, requirement of welding consumables etc. or to be estimated based on the data from
Direct Time Studies and Welding information like are time, rate of deposition, current etc. normally available in electrode manufacturers literatures and catalogure.

Welding Time standards ANALITICAL CALCULATION Analytically calculated times do not completely replace direct time studies. However, they have a number of advantages like :-

They reduce the number of studies that must be made. They can be used for predicting costs, schedules and delivery periods while estimating and quoting the firms offer. Analytical calculations are economical to apply for obtaining Time Standards for a wider coverage of operation in the plant. Whenever new sizes or new edge preparation etc. is being introduced, estimates could be made with accuracy and consistency without waiting for the job to be taken-up for production.

Welding Time standards

ANALITICAL CALCULATION
Analytical calculation of welding data, essentially involves first finding out general expression for the weight of weld metal deposited for a given edge preparation, configuration and other welding data, using previous time study results and secondary substituting the numerical values (size of the joint) in the expression to get the require data. From the weld metal weight other welding details like arcing time, welding time, consumables required can be arrived at using the data obtained from time studies and welding data hand book

Welding Time standards

ARCING TIME
The arcing time per joint is the duration of time for which the are is struck and sustained during the welding of the joint.
Arcing Time
Weight of weld metal deposited per electrode

Deposition rate of electrode gms/min

The deposition rate depends on the type of electrode, size of electrode and the current used. It can be got from Time Study results or it is supplied by the electrode manufacturer themselves (e.g.. Advani Oerlikon Welding Hand Book). Since the size of electrodes used changes for each layer, the arcing time has to be found for each layer and added to get total arcing time per joint.

Welding Time standards

WELDING TIME
The welding time can be found by multiplying the arcing time by a factor.

This factor will depend on the type of joint and nature of work can be obtained from the previous time studies on the similar work.
Also some welding data Hand Books provides these information.
Type of Fabrication Pressure Vessel fabrication Heavy machinery fabrication Railway coach under-frame fabrication Ship hull fabrication Erection welding work

Factor 2.0-2.4

1.8-3.3
2.5-3.3 1.8-2.6 3.0-4.0

Welding Time standards

CONSUMABLES REQUIRED
The weight of metal deposited by burning an electrodes is not equal to the weight of core material of the electrode. No. of electrodes
Weight of weld metal deposited per electrode Wt of weld metal yield per electrode

The actual weight of metal deposited per electrode (I.e.) Metal yield depends on the deposition efficiency for the electrode and the length of the stub thrown away after welding.
Deposition Efficiency or Metal Recovery

Weight of weld metal deposited per electrode Weight of core wire melted

Welding Time standards

CONSUMABLES REQUIRED
The deposition Efficiency will be more than 100 for iron powder electrode and less than 100 for others. If n is deposition efficiency of the electrode, L is the length of electrode and l is the length of throw away stub, then metal yield per electrode. = (Core Material Wt. Per Electrode * n/100 * (L- l) / L) This analytical calculation, at the best, can only supplement and at any rate cannot substitute Time Studies. The accuracy of the results obtained by this method largely depends on the norms got from time studies.

Practical ways to minimize Welding cost and time

Design stage

Selection of Edge Preparation

Design stage

Thickness

Design stage

Improper selection Of edge preparation Results in over welding

WRI

Practical ways to minimize Welding cost and time

During welding

Electrode Terminology

Core Wire ( Dia )

Flux Coating Stub end

Thin Coated

Thickly Coated

Electrode data
Melting time - min /electrode Diameter Time in min
3.15 mm 1.45 4 mm 1.65 5 mm 1.85 6.3 mm 2.0

Wt. Of Weld metal deposited gm/electrode Diameter

3.15 mm 4 mm 5 mm 6.3 mm

Gms/ elect.

26

38

58

90

The above data is for electrode length of 450 mm & stub length of 50 mm

RATE OF DEPOSITION OF ELECTRODES IN DIFFERENT DIAMETERS

Diameter of Electrode ( mm ) 2.00

2.50 3.25 4.00 5.00 6.30

Rate of Deposition Gms / Average Minute 11.4

12.2 19.2 25.3 35.5 51.5

Deposition Efficiency of Electrodes

Deposition Efficiency or Metal Recovery

Weight of weld metal deposited per electrode Weight of core wire melted

Deposition efficiency lies between 80 to 100 % for General Purpose electrodes

Deposition Efficiency can be higher than 100 % in iron Powder coated electrodes

Metal costs for different electrodes

Sl. No Electrode Type
General Purpose Rutile Low Hydrogen Iron Powder Deposition Efficiency % Price for 1000 Pieces Wt of metal For 1000 Pieces kg Cost of weld Metal Rs./kg

01

90 115

1112 1774

35.3 45

31.50

02

39.42

03

Rutile Iron Powder Rutile Iron Powder

140

2033

54.9

37.03

04

210

2909

82.3

35.35

Weld metal costs for different electrodes

Sl. No Electrode Type
General Purpose Rutile Low Hydrogen Iron Powder Rutile Iron Powder Rutile Iron Powder Melting Time per Electrode in mins. Material Cost of Weld metal Rs/kg. Labour cost of weld metal Rs/kg. Total cost Of weld Metal Rs/kg

01

1.90 1.70

31.50 39.42

8.24 5.80

39.74
45.22

02

03

1.85

37.03

5.16

42.19

04

2.15

35.35

4.20

39.55

Increase(Factor) in weldmetal with stub lengths

Elec. length 60 mm 70 mm 80 mm 90 mm 100 mm

250 mm 350 mm 450 mm

1.05 1.04 1.03

1.11 1.07 1.05

1.18 1.11 1.08

1.25 1.16 1.11

1.34 1.20 1.14

For stub length of 50 mm factor is 1.00

95% of the original value per Kg of electrode is lost when it becomes a scrap

COST PER KG.OF DEPOSITED WELD METAL IN RUPEES (For a 5 X 450 mm Long Electrode MR 115% Cost Rs.2437 for 1000 electrodes

Cost item

Length of the Stub thrown away

50 mm 100 mm 150 mm 200 mm

Labour

3.84 0.44 34.58

3.91 0.44 38.80

3.98 0.44 44.19

4.03 0.44 50.30

Power
Electrode

Selection of electrode diameter

Elect. Dia

3.15 mm

4.0 mm

5.0 mm

6.3 mm

3.15 mm 4.0 mm 5.0 mm

1.0 0.701 0.508

1.425 1.0 0.725

1.966 1.379 1.0

2.395 1.680 1.204

6.3 mm

0.417

0.595

0.820

1.0

Electrode changes per Kg of weld metal deposit

Electrode diameter

No.of electrode changes

3.15 mm 4.0 mm 5.0 mm

6.3 mm

36 24 14 11

Electrode is rutile type 450 mm long with DE 0f

Cost

Welding cost
Weld metal is 3-4 times costlier Wire loses 97% of its value when it becomes stub When a weldment is rejected it is more costly as consumable & labor cost is added Cost of welding increases to 165 % in Horizontal Position 294 % in Overhead position Compared to 100% in Down hand position Rework increases the cost further

Cost of Welding

05 Equipment cost 06 25 Power cost

Electrode cost

65

Labour cost
No. represents Paise

Cost items

Rutile Ty pe 60 V joint Butt 12 mm Plate Root Gap 2 mm

I Side II Side Cost Rs.

Deep penetration electrode square Butt joint Thickness 12 mm Root Gap 2.5 mm

I Side

II Side

Cost Rs.

Electrode Cost Root Run

Electrode Cost

3 Nos. 3.15 mm
5.10 mm 3.15-8mm 55 mins.
---

---

2.28

---

---

---

4.2 Nos 3.15-3Nos 62 mins.

28.00 4.4Nos.

4.4No 3.15-4mm 4-4-m

21.76

Filling-up and sealing run Labour cost

Labour and overhead costs for Gaugine out the root with pneumatic chisel

18 mins.

4.40 18 mins. 0.90 ---

18 mins

2.40

---

---

Power Cost Cost of Compressor air Total cost per meter of joint
---

-----

---

0.28 0.50 36.36

-------

---

0.20 ---

7 m2
---

-----

24.36

Excess root Gap increases the weld metal deposit

Root Gap 1 mm
Thickness Design

Root Gap 2 mm

12 790 424

16

20

12 840 502

16 1410 830

20 2120 1222

SV DV

1340 2050 704 1062

Included angle - 60 deg.

Fillet sizing

Fillet sizing with excess root gaps

Results in deposition of weld metal

Effect of root gap

WRI

Process Productivity

1.5 - 3 kg /hr.
Dia 3.15-6.3

3 - 6 kg /hr. 4 - 8 kg /hr.
Dia 1- 1.6 Dia 3.15- 6.3

SMAW

GMAW

SAW

Deposition Efficiency for welding processes Filler metal form And process
SMAW electrode 457 mm FCAW process with Solid Wire GMAW with solid wire

Deposition Efficiency %

60-70 80-90 90-97

SAW with solid wire

95-99

Loss associated with Major Arc welding Process

SMAW
Evaporation loss Spatter loss Stub loss Loss due to improper wire feeding Cut wire loss Loss due to bad handling Loss due to high currents A A A

GMAW SAW
A A NA A A NA

NA NA

A A

A A

A
A

A
A

A
NA

OPERATOR FACTOR
Represents the percentage of work day spent in actual welding (ARC Time) .

Percentage of ARC Time controls the economy of deposition of weld metal .

ARC Time varies from 10% to 50% depending upon the type of work and handling facilities. The average figure of moderately heavy and large fabrication work is approximately 40% of welders working hours. High operator factors is an indication of efficiency.

OPERATOR FACTOR
Jigs, Fixtures, Setup, Fit up are directly related to the operator factor. Their efficiency will have a great effect upon welding speed and operator comfort and safety Changing from Vertical or Overhead to the flat position can increase the welding speed as much as 400% and increase the operator factor and welder efficiency. The use of a helper will increase the operator factor.
Welding Method Operator factor %

Manual Semi-automatic
Mechanized

Automatic

5-30 10-60 40-90 50-100

REDUCING THE INPUT

Proper design of weld Joint Proper Edge Preparation

Reduce Stub End Losses (15% to 20%)

Reduction in over welding (Number of passes) Use of Higher deposition Electrodes Reducing the consumables like Gas, Electrodes filer metal etc. Reducing the Labour and Overhead Cost Proper Estimation Recycling of flux

Automation levels in welding

LOW Loading of parts Set up /assembly Tack welding Positioning while tacking Unloading Loading of assembly Welding & Positioning Un-Loading of assembly Finishing Medium High

M
M M M M M M M M

M
M/c M M/c M M M/c M M

M/c
M/c M/c M/c M/c M/c M/c M/c M/c

Automation
Manual Assembly using Jigs and fixtures Manual Tack and full welding Semi-automatic welding Mechanized welding Special Purpose welding Machines Mechanized up stream and down stream processes

Positioneering

Positioning for assembly

When the job size is big. Positioning for assembly and welding Eliminates handling time Speeds production

Eliminates the need for crane operators & other overheads

Positioning for People To eliminate fatigue of the operator To improve safety of operation

Types of Positioners & Manipulators

Turn Table Positioners Tilting-Rotating Positioners Gear Driven Positioners (135 in the horizontal plane and 360 in the perpendicular plane ) Cradle type Positioners Turning rolls for rolling cylindrical jobs Head Stock and Tail stock Positioners.

Special utility Positioners

Universal balance Positioners Welding head booms manipulators Typical columns and

Special Purpose welding machines

Production of Long seam welded Line pipes as per API 5L

Edge milling of Plates

Three roller Bending of Plates

Cylindrical correction of the Rolled Pipe edges

Pipe welding details

Root Welding

Inside Welding

Outside Welding

Tack Welding the outside of the Pipe by Co 2 Welding

Inside Welding by SAW Process

Outside Welding by Tandem SAW Process

Hydrotesting of Welded Pipes

Ultrasonic Testing of welded Pipes

Production of Long seam welded Line pipes as per API 5L

Production of Long seam welded Line pipes as per API 5L

Tack welding ( outside by GMAW )

Inside welding system

Outside welding and UT

Expansion system

Production of spiral welded pipes

Production of spiral welded pipes

Thank You