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Reducing welding costs goes beyond the usual research and development, or purchasing welding equipment at low prices. Many welding companies undermine the importance of long-term planning which takes into consideration productivity savings. If a well-conceived plan aimed at minimizing the overall welding expenses is implemented, the productivity savings will be both significant and recurring. In a nutshell, productivity savings will enable a company to keep saving even though the price spent for the welding equipment is much more costly. Many studies show that not more than 20-25% of the expenses of welding amounts to equipment and supplies, while the rest of the expenses constitute labor and other expenditures. By saving money on the material costs, the company does not stand to profit much whereas if a welding business can save even 10% on the costs pertaining to labor and other overheads, the business would have saved an 8% on the overall welding expenses. Here are some useful tips on how a company can reduce its welding costs while boosting its productivity: Research is very vital to a welding company’s growth and competence. Do some relevant research and explore different strategies on boosting your efficiency in welding. Among these include selecting the right wire diameter, voltage, travel speed, gas type, type and size of metal and others. Working with the right size of filler metal, for instance, can have a big impact on the total welding cost. A smaller size of electrode permits to amplify current density, which may have influence upon penetration. A larger size permits working with higher current, with resultant higher volume of metal deposited per unit time. These things should be well executed. The choice of the size must not be left to the welder’s prerogative. Instead, it must be objectively documented by the company in order to get the lowest possible welding cost. Energy cost estimate must also be calculated. You can come up with this data by multiplying voltage by amperage and dividing by 1000 and by the electric efficiency of the equipment, times the price per kWhr (kilo Watt hour) times the operating factor. A welding business should monitor shielding gas waste at all times. Many welders don’t know that left over shielding gases remain in delivery hoses when welding is stopped, and that extra gas is expelled when welding process is restarted. Improper handling could waste as much as 25-60% of the gases that a welding shop purchases. Improving welding safety can also save money in the long run. Ensuring the safety of the workers means reduction in expenses related to employee accidents, hospital bills, and other workmen compensation. This has to be a continuous exercise. Better consult with welding engineer and industrial safety specialist for proper welding procedures. Andrei Smith writes for Midwest Metal Products Company, one of industry’s leaders in metal forming and wire fabricating. Get the best deals in quality metal products such as point of purchase displays, trash bag stands, wire fan guards, hoop steel rings and many others. For more information, please visit www.midwestmetal.com or contact toll free #: 1.888.741.1044.
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