Welding machines are expected to be durable and serve a long life, and it is possible only when the welding machines are given routine maintenance. By no means, are the broken machines any minor interference.
When the workers have to heavily rely on welding, then the broken machines pose as the major headaches. Typically, it means expensive production loss. Even the welding machines having erratic arcs waste energy. Welds failing to pass the x-rays, ultrasonic and related tests are equally expensive for repair.
The hard failures, like the PC boards and electrically charged and burnt components, cannot be predicted. Nevertheless, the welding equipment’s owners have the ability to directly controlling the “soft failures” through worn items repairing, like that of the connections, cable, drive roll systems, internal wiring, torches, guns, and consumables. Prevention of soft failures even includes removal of corrosion along with the air-borne contaminants from the machines leading to over heating along with the circuit board failure.
Pushing deadlines coupled with the additional priorities equally cause maintenance delays, till it is much late. For these cases, it is a must to follow the instructions of the welding supervisors and pay heed to why they emphasize welding machine maintenance – the chief reasons being safety and avoiding failures.
i. Preventable Cost Efficiency
While performing the maintenance for welding machines might not be possible internally, then the ideal solution is outsourcing then so the maintenance issues are handled on time. If not treated and maintained on time, then the Preventable Cost Efficiency or PCE will rise along with the problems. PCE is the factor of the cost of production downtime per hour along with the service cost per hour. Here is illustrated calculation describing the potential savings –
PCE – Maintenance Cost / Hour
When the service provider is charging $75 per hour for the service, and the downtime is costing $500 per hour, then PCE will be 15%. So, it means spending $15 for preventive maintenance at present or paying $85 later for fixing it. The service experts firmly believe that generally, preventive maintenance helps in reducing the hard failures chances by 50%.
The equipment must be unplugged before servicing them – it includes all the 115 V plugs from the water coolers and feeders. You need to follow these established lock-out/tag-out procedures, and closely follow the safety information as given in the operator’s manual. The welding supervisors can always help, whenever you will be in doubt.
After following a regimen of apt and thorough safety and maintenance, the good welding power source from any one of the major manufacturers will be running dependably for ages. These are designed for withstanding rough usage, and using the high-quality components typically are tested for reliability and durability.
The list of proper machine maintenance includes heat distortion checking, checking the weld, and checking out for the cracks in the metal. At the time of checking these items, none should be overlooked. It is because while inspecting when something is noticed and not known till the inspection is completed. So, the welds must be checked on a regular basis, despite being perfectly straight. Any distortion signs must be checked immediately by the certified mechanical or electrical technicians, as they will be able to spot the potential problems along with the quick welds and help in avoiding expensive repairing bills in the process.