Many organizations do extensive pre-study comparing prices while buying welding equipment and consumables. Although this practice is worthy of commendation, the fact remains these buyers may more often be obsessed with initial savings of money but lose sight of long-term productivity savings, which alone can be more beneficial to the organization.

If a proper plan is conceived and implemented for reducing overall welding costs, the productivity savings will be considerable and also recurring in nature. Productivity savings will allow a company to keep saving eternally even if the price paid for the original equipment is higher.

A careful analytical study will reveal that not more than 20 to 25 percent of the cost of welding pertains to materials, while the rest of the costs are for labor and other overheads. By saving on the material costs of welding, the company does not stand to gain much whereas if a company can save even 10 percent on the costs pertaining to labor and other overheads, the company would have saved an eight percent on the total welding costs. This is true for manual or semi-automatic welding process mild steel application. Here are some ways a company can meaningfully reduce welding costs and realize productivity savings.

It is a fact that at many workplaces, the operator has to visit a tool room now and then, to collect a new contact tip, coil of wire or any other accessory. This leads to a loss of valuable productivity time.

Instead, companies should stock at least a limited supply of all necessary items – like shielding gas, flux and wire – near the welding station. One more noteworthy step would be to opt for larger spools of wire such as from 60 lb. spools to even larger packages of 1,000 lb. reels.

Welding operators should also monitor shielding gas waste. A surge turbine can be fixed at the end of the gun for a digital readout of the gas surge and flow rate. If the surge rate is high, investing in a surge guard is worthwhile as it can minimize the pressure and eliminate gas surges and waste.

One of the most common causes for wastage is over-welding from which no shop is free. The reason could possibly be due to operators not having a fillet gauge. There is also the tendency to apply some extra cover to make sure there is enough weld metal in place. Over-welding leads to avoidable waste of consumables as also valuable man hours.

Do some research to explore ways to create greater efficiency in welding. This includes examining wire diameter, wire feed speed, voltage, travel speed, gas type, transfer mode, etc. Find out ways to improve product designs to eliminate superfluous welds.

Operating under proper safety conditions will save money in the long run by reducing employee accidents and resultant workmen compensation. Constantly look for ways to reduce welding costs, increase work efficiency and improve productivity. This has to be an ongoing and continuous exercise and you will be able to realize over a period of time how much you have saved.

Constantly look for ways to reduce welding costs, increase work efficiency and improve productivity. This has to be an ongoing and continuous exercise and you will be able to realize over a period of time how much you have saved. Of course, it is a fact that different welding methods have different machine costs, labor costs, material costs, and energy costs. Besides, the use of automation and robots can drastically increase these expenses – although there may be a favorable cost-benefit ratio.

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Gavin Bone is an author for Welders. He has written articles Plasma Cutters. For information visit our site arc welder