Investing in Advanced Welding Technologies Can Boost Productivity and Efficiency

Making the job easier for workers

Obviously, there are productivity and efficiency differences between a handsaw and a chain saw. This example helps illustrate that using modern equipment and technology can improve productivity and throughput by a significant amount, while also making the job easier for workers.

Companies and fleet managers should think of welding equipment and technologies in the same way. Ask yourself: “When it comes to welding applications, am I supplying operators with handsaws or chain saws?”

Welding technologies can improve productivity, quality and safety, all while offering simple setup and ease of use for operators. Some of the features offered in advanced welding systems include point-of-use control and push-button welding parameter adjustment. In addition, advanced welding processes that make it easier for operators to achieve code-quality welds, even in challenging jobsite environments.

Technology innovations

Regardless of welding process, there is equipment and technology available that’s designed to improve productivity, quality and safety.

Advanced remote control capabilities and point-of-use welding controls can reduce the need to travel to and from the power source. This optimizes uptime at the weld joint and simplifies process changeover. This in turn helps improve overall weld quality and productivity.

Reducing the trips between the power source and the joint results in a safer jobsite, with fewer opportunities for trips and falls. This can especially make a difference on expansive jobsites, where welding may take place hundreds of feet from the power source.

Miller® XMT® 350 FieldPro™ power sources include ArcReach® technology, which provides complete remote control of the power source at the weld joint through the feeder or remote — without the need for a control cable. This eliminates the hassle and expense of special control cables and reduces clutter on the jobsite.

The system offers a remote that allows welding operators to access front panel capabilities right where they are actually welding. This technology makes process changeover easier, eliminating the need to “get by” with less than optimal settings and helping reduce weld defects.

A remote specifically optimized for stick and TIG welding gives operators the ability to remotely change process and polarity. They can also set actual amperage and detect improper connections, all without the need to swap weld cables. Another feeder is specifically designed for traditional and advanced wire processes, offering the ability to weld up to 200 feet away from the power source with no special cables — a much greater distance than cabled solutions allow. The system also saves welding parameters on a memory card for later use. The “plug and play” style of this feeder offers ready-to-weld default parameters for each process. Welding operators can simply select the process, wire type, wire diameter and gas — and start welding.

The XMT 350 FieldPro lineup also includes a polarity reversing model. With the simple push of a button, the XMT 350 FieldPro system with Polarity Reversing automatically selects the correct polarity, lead outputs and weld parameters. This prevents operators from inadvertently welding in the wrong polarity, reducing the risk of weld rework that results from incorrect cable connection. Quick process changeover also eliminates the set-up time spent switching cables and gas hoses. In addition, the system’s optimized stick and TIG arc performance is specifically designed for open root pipe welding — including process pipe and modular assembly applications — to help improve weld quality.

Advanced processes

Advanced welding processes, such as pulsed MIG and modified short circuit MIG, can also improve quality and productivity.

These advanced processes offer a more forgiving weld to help reduce weld failures. Modified short circuit MIG helps reduce training time. It can also make it easier to complete an X-ray quality weld on root passes.

The pulsed MIG process also offers smooth transfer and a controlled arc in an easy-to-use process. The technology can monitor and adjust parameters up to 10,000 times per second to maintain optimum arc conditions.

Both of these advanced welding processes are available in systems with the remote control technologies mentioned above. Welding operators can maximize productivity with the faster advanced processes while also taking advantage of the ability to change processes and parameters at the weld joint with the push of a button.

Advanced welding systems and technologies ROI

When breaking down the true cost of field welding, labor accounts for approximately 80%, while equipment accounts for about 5%. Providing welding operators with the most productive tools is among the best ways to reduce labor costs and increase efficiency.

Advanced welding technologies and processes can provide that return on investment by offering improved productivity, weld quality and safety.