How to solve 10 common challenges when welding on site | MillerWelds

Anatomy of a Jobsite

All Jobsites Have Challenges. You Can Solve Them.

Jobsite challenges like the lack of skilled welders, safety risks and rework can slow productivity and threaten timelines. Whether they’re at the weld joint, in the job environment or in managing the project or the site, Miller can help you find solutions to address them.

Weld Joint Challenges

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Time-consuming parameter changes

To avoid a long trip to the power source, some welders use non-optimal settings, which negatively affect weld quality. ArcReach® technology and Wireless Interface Control let welders set ideal processes and parameters right at the joint for better welds. On XMT® 650 ArcReach® Systems, welders can change polarity at the joint for easy switching between welding and gouging.

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Safety risks

The risk of a slip, trip and fall injury increases if a welder walks through the jobsite to change a process or parameter at the power source. ArcReach® technology and Wireless Interface Control reduce that risk because it lets welders make changes at the weld joint.

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Bad work connections

If a welding power source isn’t properly connected to the workpiece, arc interference is more likely — which negatively affects weld quality. Miller® multioperator racks let every power source easily connect to a quality common work connection, helping ensure good welds.


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Environmental Challenges

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Harsh conditions

If environmental conditions damage equipment, you get behind schedule. Miller solutions are durable, reliable and built to withstand harsh environments. XMT® 350 FieldPro™ welding power sources, XMT® 650 ArcReach® Systems and ArcReach® accessories have impact-resistant cases. Wind Tunnel Technology™ and coated circuit boards protect sensitive internal components from dirt and other contaminants.

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Dirty power

It causes unstable arcs, bad welds and rework. Miller engine drives like the Trailblazer® 325 produce the clean 120/240V power you need. Welding power sources like the XMT® 350 FieldPro™ and XMT® 650 ArcReach® Systems have Auto-Line™ Technology, which rejects voltage spikes and smooths dips to protect arc quality.

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Limited space

Crowded jobsites are harder to navigate, slowing productivity. Conserve space with multioperator racks that stack up to six welding power sources — including the multiprocess XMT® 350 FieldPro™, which replaces multiple, single-process machines. Save even more space with a dual operator engine-driven welder that provides two arcs from a single machine or an engine-driven welder that includes an air compressor, like the Big Blue® 600 Air Pak™, so you can reduce the pieces of equipment on a jobsite. Portable ArcReach® SuitCase® feeders and ArcReach® Stick/TIG Remotes make welding in tight spaces easier — and many Miller engine-drives quickly mount on trailers or running gear for easy transport and available feeder carts or sleds provide mobility as well. For applications where gouging is required, XMT® 650 ArcReach® Systems offer integrated gouging, eliminating the need for a separate power source taking up space on the jobsite.


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Job Trailer Challenges

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Shortage of experienced welders

Those who are still perfecting their craft typically aren’t as fast as more seasoned welders. Miller® solutions like the XMT® 350 FieldPro™ are easy to use; Auto-Process Select™ simplifies setting the right process, while ArcReach® technology and Wireless Interface Control, optional on select Big Blue and Trailblazer engine-driven welders, let welders make changes right at the weld joint.

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Equipment downtime

It reduces profits and productivity. Avoid repairs with solutions that are built for reliability. Miller equipment is designed for extreme working conditions with ruggedly constructed internal components to deliver the performance you need.

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Frequent weld inspections

Welds that fail inspection drive up costs and put you behind schedule. Get high-quality welds with Miller power sources and engine drives. ArcReach® technology on XMT® 350 FieldPro™ welding power sources and XMT® 650 ArcReach® Systems includes Cable Length Compensation (CLC™) technology, so the voltage set at the power source is the voltage you get at the weld joint — plus Adjust While Welding (AWW™) technology for parameter changes at the joint even while the arc is on.

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Moving equipment on the jobsite requires a lot of labor coordination, which slows productivity. Stay on schedule with ArcReach® technology and Wireless Interface Control: Welding power sources stay put and welders move around the jobsite less because they can change processes and parameters at the weld joint. ArcReach® accessories are compatible with many Miller welding power sources and engine drives, reducing the amount of equipment that needs to move around the jobsite.

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