REDEFINING ARC WELDING PERFORMANCE THROUGH PROCESS OPTIMIZATION

OPTIMIZATION RESULTS FROM TIER 1 AUTO MANUFACTURERS UTILIZING THE WELD CENTRAL® SYSTEM

Tier 1 automotive manufacturers implementing the Weld Central® Welding Optimization System have quickly seen the benefits of optimizing their systems and processes based on the data collected. Here are three examples showing potential cost savings and process improvements that can be achieved after optimizing robotic welding performance. Click here for a printable PDF with the examples below.


TIER 1 MANUFACTURER OF BODY & CHASSIS COMPONENTS
Problems Discovered:
Excess downtime due to poor contact tip life resulted in a less than desired number of welds per shift. Peak gas flow was very high due to the gas surge at each arc start, resulting in excess gas usage.
Optimization Results:
PowerBall® welding consumables were installed during a trial period to compare arc welding performance with the current torch consumables. The ROI calculator included with the Wizard View® software package showed the PowerBall® consumables lasted twice as long as the current torch consumables in use, resulting in a reduction in downtime and increased number of welds and parts produced per shift. After installation of Gas Wizard™ Gas Savers, the peak gas flow surge at arc start was reduced by 41% and resulted in a 17% reduction in shielding gas usage.
TIER 1 MANUFACTURER OF CHASSIS, BUMPERS, AND FRAMES

Problems Discovered:
After implementing the Weld Central® System, it was determined that the shielding gas flow was out of range by as much as 45 CFH and excess gas was being used due to the surge of gas at the start of each weld.

Optimization Results:
The gas flowmeter was adjusted to set the gas flow to the proper range. Gas Wizard™ Gas Savers were installed to eliminate the wasted gas occurring at the arc start. After adjusting only the flowmeter, a 21% savings on shielding gas was achieved. With the addition of the Gas Saver, shielding gas consumption was reduced by an astonishing 53%, resulting in substantial cost savings.



MANUFACTURER OF SEATING AND STRUCTURAL COMPONENTS

Problems Discovered:
Wire delivery problems were detected after data showed spikes in the wire feed motor current. Arc stability issues were also occurring, resulting in inconsistent weld quality.

Optimization Results:
After optimizing the wire delivery equipment, wire feed speed was stabilized and the feed motor current was reduced by 11% without spikes due to wire feeding issues. PowerBall® welding consumables were installed during a trial period to compare arc welding performance with the current torch consumables. The data collected from the Wizard View® software showed the PowerBall® consumables, along with the improvement in wire delivery, improved weld quality consistency by approximately 63%.


CHRIS KARCHER PROMOTED TO WELDING ENGINEER - FIELD APPLICATIONS

We are proud to announce Chris Karcher has been promoted to Welding Engineer - Field Applications. Chris was previously our Technical Sales Representative for Ohio, Pennsylvania and West Virginia. He is a graduate of Ferris State University’s Welding Engineering program and is a Certified Welding Inspector (CWI). In this new role, Chris will continue to utilize his proven track record and technical expertise in the field to solve welding challenges at facilities throughout North America. He will be at the forefront of Wire Wizard’s focus on maximizing productivity through innovative welding optimization solutions.


Chris Karcher

Connect with Chris on LinkedIn | Email: ckarcher@wire-wizard.com

PLEASE WELCOME MARK CARTER, OUR NEW TSR FOR MINNESOTA, WISCONSIN, ILLINOIS & IOWA

We are pleased to announce the hiring of Mark Carter as Technical Sales Representative for the states of Minnesota, Wisconsin, Illinois and Iowa. He brings with him over 30 years of welding expertise and has previously held long term positions with Hyundai® Welding and Fronius®, as well as owning & operating a welding and fabrication company. He has experience as an educator at Dunwoody College in Minneapolis, where he taught as a Senior Welding Instructor. Mark is a US Air Force Veteran, proudly serving his country and gaining his first experience in welding as a Metals Technology Specialist. Contact Mark today to solve your toughest welding challenges!


Mark Carter

Email: mcarter@wire-wizard.com

NOLAN NOWAK NOW PROVIDING TECHNICAL SALES FOR OHIO AND INDIANA

Effective June 1st, Nolan Nowak will now be the Wire Wizard Technical Sales Representative for the Ohio and Indiana region. Nolan is a graduate of Ferris State University’s Welding Engineering program, and has proven his welding expertise by solving difficult problems and building new relationships since he joined the Wire Wizard team last year. He has also proudly served 6 years as an Infantryman in the Army National Guard. Contact Nolan today to solve your toughest welding challenges!


Nolan Nowak

Connect with Nolan on LinkedIn | Email: nnowak@wire-wizard.com

OUR OFFICES WILL BE CLOSED MONDAY, MAY 31st IN OBSERVANCE OF MEMORIAL DAY



WIRE WIZARD® PRODUCT CATALOGS

To request printed catalogs, please call customer service at 517-782-8040 ext. 1 or email us at sales@wire-wizard.com


WIZARD TECH ONLINE TRAINING & WEBINARS
Expand your industry knowledge by learning about new products, tools and techniques to solve the toughest welding challenges. Our comprehensive online training system includes a series of training modules that cover everything from wire dispensing basics to optimizing equipment for maximum arc welding performance and productivity.

Click here for more information on the Wizard Tech Online Training Program





ELCo Enterprises, Inc. • 5750 Marathon Drive • Jackson, MI 49201
Phone: 517-782-8040 • Fax: 517-782-8039 • www.wire-wizard.com
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