How to Avoid Missed Welds - Job shop and weld several small quantity jobs

[Laser]

Have a continued problem with missing welds, any advice? We are a job shop and weld several small quantity jobs. A weld counter is out of the question right now. Any advise would be appreciated.

Thank you.

 

[Craig H.]

Re: How to avoid missed welds

A warning: I know nothing about welding or that type of work, so consider this a "stupid question/suggestion" and take it for what its worth.

Do your welders work from a blueprint or a set of plans? If so, would it be practial to have a new print for each part, and have the welder draw a line through each weld as they make it? Then, when they think they are finished they can double check their work.

Again, FWIW.

 

[Jim Wynne]

Re: How to avoid missed welds

A warning: I know nothing about welding or that type of work, so consider this a "stupid question/suggestion" and take it for what its worth.

Do your welders work from a blueprint or a set of plans? If so, would it be practial to have a new print for each part, and have the welder draw a line through each weld as they make it? Then, when they think they are finished they can double check their work.

Again, FWIW.

That's a good suggestion, Craig. If there's a continuing problem with missed welds, something like you suggest would be a good place to start.

 

[prototyper]

Re: How to avoid missed welds

Have a continued problem with missing welds, any advice? We are a job shop and weld several small quantity jobs. A weld counter is out of the question right now. Any advise would be appreciated.

Thank you.

Correct me if I'm wrong but I'm guessing you are talking about manually applied welds?

Where any process relies on the human element they will make mistakes. People can be distracted or get tired, they can misread drawings, etc.
A set routine can often be the best way to overcome some of these issues, backed up with visual aids.

Have you thought of taking photographs of a good part and numbering the welds, the welder should then weld as per the sequence indicated.

You could take this a step further and create Standard Operating Procedures (SOP) which detail what should be done at each part of the operation and including the visual aids.

You could also consider introducing "neighbour" or "buddy" checks, where the next person in the process checks the work done at the previous operation. Bear in mind that this is also reliant on the human element and can stop the majority of faults but is not 100% effective.

 

[SteelMaiden]

I have seen "travelers" introduced in an Ag equipment manufacturer for this problem. Welds are called out by locations, and the welders sign off that they've done theirs, as well as a visual confirmation that the welds from the previous station are, in fact, all present.

 

[Jim Wynne]

I have seen "travelers" introduced in an Ag equipment manufacturer for this problem. Welds are called out by locations, and the welders sign off that they've done theirs, as well as a visual confirmation that the welds from the previous station are, in fact, all present.

That's a good point. It's a good thing for the next operation to verify that the previous operation was correctly completed before adding more value. I've seen cases where welding was done and the next operation was completed (painting, e.g.) before the missing weld was discovered. It's usually just a quick visual and doesn't take a lot of time.

 

[Laser]

That's a good point. It's a good thing for the next operation to verify that the previous operation was correctly completed before adding more value. I've seen cases where welding was done and the next operation was completed (painting, e.g.) before the missing weld was discovered. It's usually just a quick visual and doesn't take a lot of time.

Normally welding is the last operation here, prior to shipment to the customer.

Appreciate the responses and look forward to additional comments.

 

[SteelMaiden]

They implemented this, and their production actually improved, and customer complaints went down. The welders had a visual, and they felt confident as well as knowing someone had their back. A lot of welds go into something like a feeder wagon.

 

[Vic de Beer]

If you have several welders, try and determine if it is one welder that misses the welds, or some of them (each welder should identifiy his welds - some welding standards require this).
If it is problem with one welder only, it is no problem.... have his chargehand or supervisor keep a closer eye on him.(or the welding inspector)
If it a problem with more than one welder, hold them back one lunchbreak and give them a short training session on how to identify their work (just like an artist would write his name on a painting )

 

[Laser]

If you have several welders, try and determine if it is one welder that misses the welds, or some of them (each welder should identifiy his welds - some welding standards require this).
If it is problem with one welder only, it is no problem.... have his chargehand or supervisor keep a closer eye on him.(or the welding inspector)
If it a problem with more than one welder, hold them back one lunchbreak and give them a short training session on how to identify their work (just like an artist would write his name on a painting )

If its multiple welders missing welds, its more a processing issue?