Simple Ways Filler Metal Packaging Can Yield Cost and Time Savings
How can you reasonably “cut corners” in your welding operation and still maintain a high-level of productivity, quality and profitability? Try these solutions.
Posted: April 10, 2010
These days, we all need to find ways to save money and get the job done faster . . . and with fewer resources. So how can you reasonably "cut corners" in your welding operation and still maintain a high-level of productivity, quality and profitability? One way that could help is by selecting the most appropriate filler metal packaging.
Filler metal manufacturers offer product in packages of varying sizes, styles and weights, all of which are designed to meet the needs of specific applications and ? with the right selection ? can contribute significantly to your overall efficiency.
So, where should you start when considering which filler metal package is right for you? Size and weight. Make certain that your welding operation has a filler metal drum or spool that is large enough to compensate for the volume of product you are producing. Doing so will minimize unnecessary downtime for drum or spool changeover and help ensure that you and your welding operators spend time and energy instead on activities that positively affect your throughput.
Conversely, try not to use a filler metal packaging that is so large that you find you are keeping the product on the floor for an extended period of time. If kept in the welding operation for too long, filler metals have an increased risk of accumulating moisture, dust, oil or other contaminants that can affect their performance. And a poor performing filler metal can ultimately lead to quality issues and/or rework that can will adversely affect your welding operation's productivity and bottom line.
Simply put, use smaller packaging for smaller volume operations and increase as needed for larger ones. Your local welding distributor can help you make an informed decision as to when and how to upgrade to a larger package to meet the needs of your particular size welding operation.
Selecting an appropriate size and weight of packaging, however, is just the start. Be certain, also, to choose the right type of packaging for your welding operations to help minimize downtime for waste removal. This may seem like a minor consideration, but the time, labor and cost of package breakdown and disposal can have a significant impact on productivity and profitability.
To help address this problem, many filler metal drums available in the marketplace are now 100-percent recyclable, which reduces the labor and downtime needed to dispose of them, as they do not require welding operators to separate metal and fiber parts or transport them into separate waste containers. There are also steel reels that can be scrapped for recycling, again minimizing labor for waste disposal.
Proper storage and/or placement of your filler metal packaging can also contribute appreciably to the effectiveness of your welding operation. First, be certain the package is in a place in the welding cell where it doesn't obstruct workflow. Also, avoid double-stacking drums, spools and reels as this can damage the filler metal and lead to quality issues, rework and lost productivity.
Keep a reasonable amount of inventory in a storage area that is easily accessible from the welding cell. Doing so helps prevent unnecessary stoppages in the welding operation and also eliminates long, timely trips to obtain new packaging when the welding operation requires a filler metal changeover. Keeping the storage area temperature relatively consistent and dry, and rotating stock regularly can also help prevent downtime for addressing weld quality issues that may arise later on from damaged filler metals.
Remember, choosing a filler metal package that best fits your welding operation and caring for it properly can reduce unnecessary downtime for drum or spool changeover and provide you with greater arc-on time. With fewer changeovers, you can be sure that your welding operators are spending time contributing positively to the throughput of product rather than spending it moving, retrieving and replacing that packaging. Too, the right package can help ensure you get the best performance out of your chosen filler metal and reduce costly rework that may negatively affect your company's bottom line.
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Tim Hensley is distribution manager for Hobart Brothers, 101 Trade Square East, Troy, OH 45373, 800-424-1543, hobartbrothers.com, .
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