First Pass Yield - Welding Process Improvement

T

Tratori

#1
hi all, this is my first discussion in this great forum and I hope to learn much from you all.

I'm working on implementing FPY project in one of our cells. we had FPY of 54% in Welding process which is ver very low and affecting our CoQ.

any Idea how to improve the welding process? My manager think of doing Training plan for the welders, I'm not familiar with planning much.

anyone help please ?

Thanks in advance :bigwave:
 
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Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#2
Re: FPY - welding process improvement !!

Welcome to the Cove! :bigwave:

Welding is a big subject. Let us think it terms of man-material-machine-environment. In order to know whether training would help, first there should be a review of materials, machine and environment. Diagnosis of welding problems requires symptoms, but we also need to know what welding process you are using. Arc? Mig? Tig? Something else? What material is being welded? What rod/wire and/or gas is being used?

So please tell us what welding process is involved, and the types of weld flaws. There can be many factors, and sometimes more than one combined.
 

kgott

Quite Involved in Discussions
#3
I think your manager is right. You will need to train and let welding operators practice for the standard they need to meet.

Part of your plan will need to address reducing variation in the variables which means you will need to calibrate your welding machines so that amp and voltage are accurate. I assume you are using a welding specification for each type of process used and for each type of joint weld.

You may even need to calibrate the hot box's if you use the manual metal arc process.

Its been a long time but Im sure there is an ASME standard where all this is set out. You might like to get customer input or approval for the design and specification and standard for welds.

This is applicable processes used a Jennifer said, materials used and any NDT requirements. Once you've got all this sused then you can train your welding operators to meet the standard.

You will also need to establish an in process inspection plan to test completed welds on a random or specified basis
 

DRAMMAN

Quite Involved in Discussions
#4
When ever I work on a project to improve very low yields I start with the basics.

-is the process documented.
-is the process mapped.
-Operator training
-equipment calibration and maintenance
-fixturing
-quality of equipment, consummables, fixturing
-Are you tracking your defects with a basic Pareto chart. Attck the #1 issue and then move to #2.
-Do an PFMEA.
-5S the work area.
-Set-up procedures and verification.
 
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