Unlock Your Potential - Hobart Brothers
Unlock Your Potential - Hobart Brothers
Unlock Your Potential - Hobart Brothers
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<strong>Unlock</strong> <strong>Your</strong> <strong>Potential</strong><br />
solutions for continuous improvement
solutions for continuous improvement<br />
STEP 1:<br />
Discovery<br />
OUR GOAL:<br />
TO UNCOVER CONTINUOUS IMPROVEMENT P O T E N T I A L<br />
STEP 2:<br />
Identify<br />
Key Drivers<br />
THROUGH IDENTIFICATION OF KEY VALUE A N D<br />
NON-VALUE ACTIVITIES IN THE FABRICATION PROCESS.<br />
STEP 3:<br />
Documentation<br />
Review &<br />
Proposal<br />
MEASUREABLE BENEFITS TO THE CUSTOMER:<br />
INCREASED OUTPUT<br />
OVERALL WELDING COST REDUCTIONS<br />
IMPROVED QUALITY<br />
STEP 4:<br />
Implementation<br />
STEP 5:<br />
Monitoring &<br />
Verification
solutions for continuous improvement<br />
In-depth analysis by industry experts shows that labor is the major cost driver<br />
in most fabrication operations. Our goal at <strong>Hobart</strong> <strong>Brothers</strong> is to help you reduce labor for<br />
non-value-added activities—those tasks that don’t contribute to your overall productivity<br />
or bottom line. And we can lower your overall costs along the way.<br />
How? With our exclusive Improvement <strong>Potential</strong> (IP) Methodology that looks at:<br />
PRE-WELD ACTIVITIES<br />
WELD ACTIVITIES<br />
POST-WELD ACTIVITIES<br />
This approach helps you identify the potential for productivity improvements and<br />
cost savings in your fabrication operation, specifically where most non-value-added<br />
labor occurs: in the pre- and post-weld areas.
solutions for continuous improvement<br />
Consider the cost breakdown of a typical welding process:<br />
Labor 85%<br />
Electrode 10%<br />
Power 2%<br />
Gas 3%<br />
In many welding operations, a large percentage of the labor (as shown here) is<br />
non-value-added. It is used for costly activities like grinding, sandblasting or chipping that may<br />
not be necessary—and that could be lowering your potential for greater productivity.<br />
We can help you determine if these activities exist in your welding operation.
“The technical support we received throughout<br />
the conversion process can’t be touched. Our<br />
<strong>Hobart</strong> representative showed how we could<br />
improve our weld quality and productivity with<br />
a new wire, plus reduce our clean up. These<br />
benefits were the real selling point.”<br />
MILT SIESKY, SENIOR INDUSTRIAL ENGINEER/WELDING, JLG<br />
MCCONNELLSBURG, PA
solutions for continuous improvement<br />
Step 1: Discovery<br />
<strong>Hobart</strong> <strong>Brothers</strong>’ Improvement <strong>Potential</strong> (IP) Methodology focuses first and foremost on<br />
developing a long-term, mutually beneficial partnership between our company and yours.<br />
It’s an approach we believe in and it begins by listening to your needs.<br />
We first engage in a sharing discussion and a brief walk though your facility. Our objective<br />
is to identify areas of your welding operation that can be enhanced. We also look<br />
for non-value-added activities that may be hindering your productivity and/or<br />
unnecessarily increasing your costs.
“The <strong>Hobart</strong> team helped us get the right<br />
parameters for our metal-cored wire and<br />
provided more technical support than I’ve gotten<br />
from any other company. It was phenomenal.<br />
Plus, with the metal-cored wire, we’ve gotten<br />
nearly a 30 percent increase in productivity<br />
with our robots.”<br />
CARL BAATZ, PLANT MANGER, SQUARE DEAL MACHINING<br />
MARATHON, NY
solutions for continuous improvement<br />
Step 2: Identify Key Drivers<br />
<strong>Hobart</strong> <strong>Brothers</strong> has highly trained experts that work directly on the shop floor to identify<br />
key problems that you and your team can then prioritize. Depending on your particular welding<br />
operation, we can even provide robotic or process support to help in the assessment.<br />
Some of the areas of the welding operation we examine during the IP Methodology process are:<br />
Part<br />
Movement/<br />
loading<br />
Part<br />
Movement/<br />
Indexing<br />
Part<br />
Movement/<br />
Unloading<br />
Pre-<br />
Cambering<br />
Sand<br />
Blasting<br />
Arc-on<br />
Time<br />
(Welding)<br />
Air<br />
Movement<br />
Weld<br />
Repair<br />
Reject<br />
Sand<br />
Blasting<br />
Fill-up<br />
& Tack<br />
Antispatter<br />
Application<br />
Pre-weld<br />
Activities<br />
Blending<br />
Grinding/<br />
Blending<br />
Antispatter<br />
Application<br />
Weld<br />
Activities<br />
Grind/<br />
Blend<br />
Fill-up &<br />
Tack<br />
Part<br />
Cleaning/<br />
Rinsing<br />
Post-weld<br />
Activities<br />
Chipping/<br />
Scraping<br />
Grinding/<br />
Blending
“Our IP (Improvement <strong>Potential</strong>) Methodology<br />
helps us help our customers. It’s exciting to<br />
provide the tools they need to uncover<br />
productivity increases and cost reductions<br />
in their welding process.”<br />
DOUG KREBS, HOBART BROTHERS<br />
BUSINESS UNIT MANAGER
solutions for continuous improvement<br />
Step 3: Documentation Review & Proposal<br />
After compiling data into a final report, <strong>Hobart</strong> <strong>Brothers</strong>’ experts review their<br />
findings with you in an open forum. Depending on the data collected, the report<br />
may include suggestions for alternative methods, materials and/or processes, or we<br />
may conclude that additional information or verification is necessary.<br />
It’s then your decision whether to implement some, all or none of the suggestions<br />
we’ve provided.
“It’s rewarding to know that we can analyze a<br />
customer’s fabrication process and then offer<br />
them a real solution to increase their<br />
productivity. It’s even better to see what a<br />
difference it can make on their bottom line.”<br />
PETER CORTINA, HOBART BROTHERS<br />
BUSINESS DEVELOPMENT MANAGER
solutions for continuous improvement<br />
Step 4: Implementation<br />
We recognize that your time is valuable. Should you proceed with the improvement proposal<br />
<strong>Hobart</strong> <strong>Brothers</strong> provides, we will be with you every step of the way. Our goal is to provide<br />
seamless and prudent transitions and also to offer the resources you need to be successful.<br />
These include:<br />
~ WELDER TRAINING<br />
~ CLASSROOM TRAINING<br />
~ MACHINE SET-UP<br />
~ ROBOTIC SUPPORT<br />
~ PART RUN-OFFS<br />
~ METALLURGICAL ANALYSIS<br />
~ ETCHED CROSS-SECTIONS
“There are so many factors that affect a<br />
customer’s total weld cost. That’s why our IP<br />
Methodology analyses the entire fabrication<br />
process, not just the welding process. It<br />
especially let’s us look at ways to eliminate<br />
pre- and post-weld activities and lower our<br />
customer’s overall costs in those areas.”<br />
RICK CONRAD, HOBART BROTHERS<br />
BUSINESS DEVELOPMENT MANAGER
solutions for continuous improvement<br />
Step 5: Monitoring & Verification<br />
‘<strong>Hobart</strong> <strong>Brothers</strong>’ support doesn’t end after implementing<br />
your improvement proposal. Our representatives follow-up<br />
regularly to monitor all areas of your operation, including<br />
your pre- and post-weld areas. We want to verify that<br />
your welding process is reaching it’s productivity and<br />
cost-savings potential.’
<strong>Hobart</strong> <strong>Brothers</strong><br />
Key Account Management (KAM)<br />
Summary Report
Power R<br />
Power Supply Efficiency<br />
75 %<br />
Weld Metal Deposition Summary<br />
de / Zip Code V4N 4G7<br />
Pr<br />
Welding Procedure Detail<br />
Current Procedure<br />
Total # of Weld Passes<br />
Procedure Variables Information<br />
Number of Weld Passes<br />
Welding Process<br />
Operator Factor [%]<br />
Electrode Brand Name<br />
Electrode Classification<br />
Type of Gas / Flux<br />
Deposition Efficiency [%]<br />
Gas Flow or Flux Ratio [cfh or flux/wire]<br />
Electrode Diameter [in]<br />
Welding Voltage [volts]<br />
Wire Feed Speed [in/min]<br />
Electrode Stick-out [in]<br />
Welding Current [amps]<br />
Welding Travel Speed [in/min]<br />
Theoretical Deposition Rate [lbs/hr]<br />
Actual Deposition Rate [lbs/hr]<br />
Consumable Cost Information<br />
Electrode Cost [$/lbs]<br />
Gas / Flux Cost [$/ft3 or $/lbs]<br />
Additional Information<br />
Pre-weld Time [min]<br />
Post-weld Time [min]<br />
Additional Variable Costs [$]<br />
New Procedure<br />
Total # of Weld Passes<br />
1<br />
Process 1<br />
1<br />
[00] GMAW (Man)<br />
65<br />
Esab S-6 Solid Wire<br />
AWS E70S-6<br />
[G] Ar / 8-10% CO2<br />
91<br />
40<br />
0.045<br />
30.0<br />
425<br />
0.75<br />
300<br />
10.44<br />
11.48<br />
6.79<br />
1.33<br />
0.03<br />
Joint Information<br />
Current Procedure<br />
Cycle Time<br />
Heat Input Summary<br />
Weld Consumable Usage Summary<br />
Electrode Consumed [lbs]<br />
Gas / Flux Consumed [ft3]<br />
Power Consumed [kWh]<br />
Procedure Cost<br />
17.00<br />
Description remove mill scale from blade / apply anti spatter<br />
45.00<br />
Description chip and clean spatter<br />
3.00 Description anti spatter spray and grinding wheels etc.<br />
17.00<br />
45.00<br />
3.00<br />
1<br />
Process 1<br />
Substantial<br />
Savings!<br />
New Procedure<br />
Joint Type<br />
Total length of weld joint<br />
Weld Metal Deposited [lbs]<br />
Weld Metal Required by Weld Joint [lbs]<br />
Overweld (Underweld)<br />
Pre-weld Time [min]<br />
Total Welding Time [min]<br />
Post-weld Time [min]<br />
Cycle Time [min]<br />
Heat Input [kJ/in]<br />
Pre & Post Weld Labor [$]<br />
Welding Labor [$]<br />
Total Electrode [$]<br />
Total Gas / Flux [$]<br />
Power [$]<br />
Additional Variable Expense(s) [$]<br />
Procedure / Process Total Cost<br />
96 Inch Loader Bucket : Case Example<br />
Fillet - Flat<br />
73 ft<br />
191.09<br />
51.7<br />
16.05<br />
55.94<br />
16.78<br />
77.50<br />
161.36<br />
21.35<br />
1.68<br />
1.34<br />
3.00<br />
$266.23<br />
T o t a l<br />
14.61<br />
14.60<br />
0.0%<br />
17.00<br />
129.09<br />
45.00<br />
$266.23<br />
Cross<br />
Procedure Variables Information<br />
Number of Weld Passes 1<br />
Welding Process [30] MCAW (Man)<br />
Operator Factor [%]<br />
65<br />
Electrode Brand Name [3] Corex 6XC (Canada)<br />
Electrode Classification CSA E4801C-6-CH<br />
Type of Gas / Flux [G] Ar / 8-10% CO2<br />
Deposition Efficiency [%]<br />
97<br />
Gas Flow or Flux Ratio [cfh or flux/wire]<br />
40<br />
Electrode Diameter [in]<br />
0.062<br />
Welding Voltage [volts]<br />
28.0<br />
Wire Feed Speed [in/min]<br />
300<br />
Electrode Stick-out [in]<br />
1.00<br />
Welding Current [amps]<br />
310<br />
Welding Travel Speed [in/min] 14.02<br />
14.46<br />
9 . 1 1<br />
Consumable Cost Information<br />
Electrode Cost [$/lbs]<br />
1.67<br />
Gas / Flux Cost [$/ft3 or $/lbs]<br />
Theoretical Deposition Rate [lbs/hr]<br />
Actual Deposition Rate [lbs/hr]<br />
9.00<br />
1.00<br />
Additional Information<br />
Pre-weld Time [min]<br />
Post-weld Time [min] 9.00<br />
Additional Variable Costs [$]<br />
1.00<br />
Note : Numbers shown on this report are estimates only, any changes will modify the results<br />
Cycle Time<br />
Heat Input Summary<br />
T o t a l<br />
Weld Metal Deposited [lbs] 14.60<br />
Weld Metal Required by Weld Joint [lbs] 14.60<br />
Overweld (Underweld) 0.0%<br />
Pre-weld Time [min]<br />
Post-weld Time [min] 9.00<br />
Total Welding Time [min] 96.13<br />
Cycle Time [min] 105.13<br />
Heat Input [kJ/in] 37.1<br />
Weld Consumable Usage Summary<br />
Electrode Consumed [lbs] 15.05<br />
Gas / Flux Consumed [ft3] 41.65<br />
Power Consumed [kWh] 12.05<br />
Procedure Cost<br />
Pre & Post Weld Labor [$] 11.25<br />
Welding Labor [$] 120.16<br />
Total Electrode [$] 25.14<br />
Total Gas / Flux [$]<br />
Power [$] 0.96<br />
Additional Variable Expense(s) [$] 1.00<br />
Description no grinding on blade requirred<br />
Description less spatter to clean<br />
Description less grinding disk/wire wheel usage<br />
Procedure / Process Total Cost $158.51<br />
$158.51<br />
Note : Numbers shown on this report are estimates only, any changes will modify the results
<strong>Hobart</strong> Distributors<br />
To locate your nearest <strong>Hobart</strong> distributor call 1-937-332-4000 or 1-937-332-5188<br />
or visit our Web site www.hobartbrothers.com<br />
Headquarters<br />
<strong>Hobart</strong> <strong>Brothers</strong> Company 101 Trade Square East Troy, OH 45373 Phone: 937-332-4000 Fax: 937-332-5700<br />
International Headquarters<br />
Phone: 937-332-5188<br />
FAX: 937-332-5064<br />
Regional Office - Canada<br />
Canadian Welding Products Group<br />
Phone: (519)-537-6291<br />
Fax: (519)-421-0480<br />
Regional Office - Middle East<br />
Phone: +971-4299-6621<br />
FAX: +971-4299-6681<br />
E-mail: itwme@emirates.net.ae<br />
Regional Office - India<br />
Phone: +91-222520-7388<br />
FAX: +91-222520-7389<br />
E-mail: itwweldi@satyam.net.in<br />
Regional Office - Asia<br />
Phone: 65-6552-1223<br />
FAX: 65-6552-1929<br />
E-mail: vmarta@millerwelds.com<br />
Beijing Miller Electric<br />
Phone: +86-10-8739-7900<br />
FAX: +86-10-8739-7600<br />
E-mail: lisa.li@millerchina.com<br />
Regional Office - Brazil<br />
Phone: +55-11-5514-3366<br />
FAX: +55-11-5891-7679<br />
E-mail: itwsoldagem@osite.com.br<br />
Web site: www.itwsoldagem.com.br<br />
Regional Office - France<br />
Phone: +33-1-6004-1166<br />
FAX : +33-1-6004-8860<br />
E-mail: miller@itw-welding.fr<br />
Web site: www.miller-france.com<br />
Regional Office - Italy<br />
Phone: +39-02-9829-0218<br />
FAX : +39-02-9828-1552<br />
E-mail: millerit@itw-welding.it<br />
Regional Office - Netherlands<br />
Phone: +311-866-41456<br />
FAX : +311-866-49020<br />
E-mail: info@itw-welding.nl<br />
Web site: www.itw-welding.com<br />
Regional Office - Mexico<br />
Phone: +52-55-5366-7370<br />
FAX : +52-55-5366-7376<br />
E-mail: jflore@millerwelds.com<br />
Web site: www.itwweldingmexico.com<br />
Welding Industries of Australia<br />
Phone: +61-1300-300-884<br />
FAX: +61-8-827-66327<br />
E-mail: intc@welding.com.au<br />
Web site: www.welding.com.au<br />
Weldwell New Zealand<br />
Phone: +64-6-834-1600<br />
FAX: +64-6-835-4568<br />
E-mail: admin@weldwell.co.nz<br />
Web site: www.weldwell.co.nz<br />
Regional Office - Northern Europe<br />
Phone: 46-031-726-4600<br />
FAX: 46-031-726-4700<br />
E-mail: per.gelang@itw-welding.se<br />
Web site: www.elga.se<br />
Regional Office - Russia<br />
Phone: +7-812-961-5481<br />
E-mail: infosvarka@itw-welding.ru<br />
Web site: www.itw-welding.ru<br />
Regional Office - Spain<br />
Phone: 34-963935398<br />
FAX: 34-963629516<br />
E-mail: vcubero@itw-welding.es<br />
Regional Office - Africa<br />
Phone: +44-7770562799<br />
FAX: +44-1204-473039<br />
E-mail: Andy.Foster@itw-welding.co.uk<br />
Web site: www.itw-welding.co.uk<br />
Regional Office for:<br />
Colombia, Venezuela,<br />
Trinidad & Tobago, Panama<br />
Phone: 920-968-7508<br />
FAX: 920-735-4125<br />
E-mail: mferna@millerwelds.com<br />
Ecuador, Peru, Bolivia, Chile,<br />
Argentina, Uruguay, Paraguay<br />
Phone: 920-968-7508<br />
E-mail: mferna@millerwelds.com<br />
Guatemala, El Salvador, Honduras,<br />
Nicaragua, Costa Rica, Belize<br />
Phone: 525553667370<br />
FAX: 525553667388<br />
E-mail: ventas@itwwelding.com.mx<br />
Bahamas, Barbados, Dominican<br />
Republic, Jamaica, Puerto Rico,<br />
Virgin Islands<br />
Phone: 937-332-5188<br />
FAX: 937-332-5064<br />
E-mail: quafile@hobartbrothers.com<br />
Manufacturers:<br />
Tien Tai Electrode Co., LTD<br />
Phone: 886-6-2663721<br />
Fax: 886-6-2664301<br />
Web site: www.tientai.com<br />
Tien Tai Electrode (Kun Shan) Co.<br />
Phone: 86-51257446669<br />
FAX: 86-51257448416<br />
E-mail fuhu.chen@tientai.com.cn<br />
Web site: www.tientai.com<br />
Elga AB<br />
Phone: +46-31-726-46 00<br />
FAX: +46-31-726-47-00<br />
Web site: www.elgawelding.com
<strong>Hobart</strong> <strong>Brothers</strong> Company<br />
101 Trade Square East<br />
Troy, OH 45373<br />
www.hobartbrothers.com
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