Why Position?

Position for Productivity & Profits

Positioning large components for welding and assembly using cranes, chains, grippers and slings is always time consuming and hazardous. Rarely is the assembly in an optimum position for the most efficient use of manpower or equipment. Repeated repositioning can impair production schedules. Repeatability of positioning and alignment, from assembly to assembly, is virtually impossible.

The proper positioner will offer a number of advantages:

  • Improved weld quality
  • Simplified tool access
  • Consistent repeatable assembly procedures
  • Higher productivity and reduced consumables
  • Proper ergonomics with reduced operator fatigue and injury risk
  • Higher throughput and profits

 

What is the most effective method to improve production output and reduce cost?

  • Typically 85% of your cost to weld is in labor and overhead
  • Only 15% of your cost to weld is in the consumables
  • Lowering the cost on shielding gas and consumables has little effect on the bottom line, while increasing manufacturing and assembly efficiency will result in a significant COST SAVINGS and PROFIT.

 

Weld Quality

  • Utilizing a positioner can avoid inverted or vertical welding positions improving both weld quality and deposition rate

Example

Typical T joint weld ½" fillet 30 foot long.

A poorly positioned part is limited to a 5/16" weld and requires a double pass with many restarts to meet a 1/2" weld size (AWS-D1.1).

In the 1F position, the operator can increase his .052 metal cored wire feed speed to 450-500 ipm. He can now meet code for 1/2" weld in a single pass. This eliminates the 30 or so restarts for each pass and increases deposition from 9 pounds per hour to 14½ pounds per hour. All that is changed is weld position and wire feed speed! No additional investment.

Proper weldment/assembly alignment affords better access and efficiency:

  • Welding, Cleaning, Grinding, Deburring, Drilling, Bolting, Blasting
  • Assemblies can be consistently positioned for manual weld, programmed welding procedures or robotic operations

Consistent repeatable welding or assembly procedures

  • Reliable positioning will allow improved production time
  • Repeatable assembly processes support reliable production and manpower schedules

Higher productivity and reduced consumables

  • The example above illustrates an increased weld deposition rate from 9 to 14½ pounds per hour - this is a 37.9% improvement in welding productivity
  • Reduced time to position and reposition assemblies
  • Improved welds reduce consumable consumption

Proper use of other capital assets

  • Cranes, fork trucks or other lifting equipment is not tied up supporting weldments and can be used in other material handling functions

Improved ergonomics and reduced risk

  • Welding or assembly procedures can be positioned for easy access by the worker
  • Reducing employee fatigue improves production, employee morale and reduces injuries
  • Securely positioned assemblies reduce assembly and repositioning hazards

Higher throughput and profits

  • Fixed base or adjustable base positioners have boosted plant throughput 35% or more
  • Increased plant throughput will offer significant profit advantages