4 Ways To Reduce Welder Training Time in Manufacturing | MillerWelds

4 Ways To Reduce Welder Training Time in Manufacturing

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How much time does your operation spend on training? These tips can help you get new welders into production faster.
Operator welds on a part with training instructions on a screen behind them

Train new welders faster with new technologies

Many welding environments are changing as the industry evolves. Improving productivity and getting new welders up to speed are big issues for many operations. How much time does your operation spend on training? 

When welders are inexperienced or they aren’t properly trained, it can result in slower production, rework, more scrap and other associated costs. Proper training is important to achieve the quality required, but is there a way for manufacturers to reduce the time spent on it?

Tips for welder training: 

Tip 1: Get help from new technologies

Machines that are difficult to set up and adjust usually require additional training. Some of today’s welding power sources remove complexity and are designed to make setup and parameter selection easy. With preset parameters and other intuitive setup options, it’s easier and faster for welders of all skill levels to choose optimal parameters for producing quality welds. 

EZ-Set technology, available on Miller® Deltaweld® systems, simplifies parameter setup based on material thickness — removing complexity and reducing welder training time.

 

EZ-Set Technology

MATERIAL THICKNESS

Tip 2: Follow the data

If rework and missed welds are problems in your operation, analyzing weld data can help. A weld data monitoring system can track weld quality within individual cells. This technology may be configured to monitor many types of weld parameters and to catch and contain weld defects before parts leave the weld cell. This can significantly reduce costly downstream work. 

The Insight Centerpoint™ solution from Miller helps reduce training time by guiding welders through the weld sequence in real time using visualizations of the part. Embedded videos, images, audio and other file types can give welders clear, complete guidance in the fabrication process. The system can also alert welders if a weld is missed or is outside of acceptable parameters, allowing it to be corrected cost-effectively. 

Operator welds on a part with training instructions on a screen behind them

Tip 3: Think about a welding process change

If you want to reduce rework and training time, switching to a different process can offer many benefits in a manufacturing operation.

The Accu-Pulse™ process from Miller provides a 28% wider operating window and a more forgiving arc, compensating for variations in operator technique. This helps welders of any skill level get into production quicker.

Standard MIG Welding: Narrow Operating Window
Experienced Welders
Standard MIG Welding: Narrow Operating Window
New Welders
Accu-Pulse™ MIG Welding: Wider Operating Window
All Welders


Tip 4: Reconsider the filler metal

Welders must be able to read their puddle fluidity and bead size to determine if they are overwelding or underwelding. Knowing that the puddle is flowing and wetting into the base metal is critical to laying down a good weld.

Part of this is experience and technique, but filler metal also plays a role. Some filler metals are more forgiving than others. It’s possible that a change to a different filler metal — such as a metal-cored wire — can provide a more fluid puddle that wets in well and is easier to use for welders, or that delivers a cleaner metal transfer with less spatter. 

Tight closeup image of welding gun during welding in a shop

Faster welder training 

Whether your operation has an in-house training program for new welders, or you are putting welders directly into production so they can learn as they go, finding ways to make training more efficient can deliver significant time and cost savings. Investing in new solutions or making changes in the welding operation can shorten training time — and help welders of all skill levels produce high-quality welds. 

 This article is part of a series on unlocking productivity in manufacturing welding operations.  
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