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How do I do work instructions? A. Is this existing or new work?  Existing work is relatively simple to do. B. Is this a single or multiple shift operation?  Multiple shift operations are somewhat more difficult as you are dealing with a possible three different ways of doing.

C. Is this one of those new democratic shops that have teams?

If this is the case then get multiple shifts to agree on one way of doing the job and get the team involved. This gives them ownership into the process. This will go a long way towards making the process work.

Fire the knuckle dragger foreman and institute the lead man concept.

There is some excellent time study-process software available that will run on a laptop with an attached camera.

Also software that will run on your tablet with drop down options for developing work instructions.

Throw away the clip board and stop watches. They went out with the Commodore Computer.

 Welding instruction software is a bit different though, as you well know.

I started learning visual basic and C++ so that I could develop a software that would handle all the requirements of an welding IE. But, now being retired this six years, and having the time to do it, I have no real need of it. It would be a dream to sit down and punch in the weld joint, materials, sizes, weights and what ever else, the software selects a PQR or stored WPS, WPQ and plugs it into your work instructions.  The cost of doing the work and time involved would also be figured. From there it plugs this into the inherent line design portion and balances it against stored processes of the same series. Also the pictures taken of the operation on the shop floor, along with the notes of tooling, hand tools, special notes, sketches, parts needed, and what ever else. There could be a separate portion that deals with welder qualification and certification.  Any ideas? Maybe build on the TWI weld application idea.    all yours for only one easy payment . € xxxxx This is the modern way to do work study and instructions. You only have to write it once and that into the computer and make the result accessible to the man with the welding gun.


Rarely will your workups be actual. Always look at it as simply a possible way.

Rarely is casting thickness the size required. It always seems to be thicker. (After all, they sell castings by the lb.) One structure that I was costing, had castings designed to be 38 mm thick. The joint was 1500 mm long, a 45 double bevel and a 6 mm root.  Switching to English measures for simplicity; gives us 79.71 cubic inches or 22.17 lbs of weld.  That is a lot of weld metal. Welcome to the world of over 300 ton capacity haul trucks.

The first castings come in and they are machined according to the print. The welder sets up the structure and guess what? You are called to the shop floor and find that castings are sold by the pound and are rarely the minimum thickness.  One of the castings is 7mm thick 1.85 inches. Just a little extra strength built in.

This joint is 1.6” at the face.

Using about 8.4 lb per hour, it will take 22.17/10.2 = hours of arc time.Say 45 cu ft of shield gas per hour = 159.53 cu ft at .35 cu ft = 55.83.      28.36 lb of wire at 2 bucks a lb=56.72.     3.54 hr * 74.00.    SVC=261.96. Add it all together = about $375.    82 bucks difference on one weld.  35% not bad. Four welds to a structure = $328 per structure

You were only 35% off on the cost and floor to floor time and it wasn’t even your fault…

The first thing you do is to show the work up to your boss. Join teams with engineering and purchasing to add a machining pass to both parts  holding the thickness at 38 mm.  Everybody is happy, especially the guy doing the welding and the bean counters.  $328 per structure and 600 units a year=$196000 savings by adding one simple mill pass.  Not bad.  Gold star for you. All this is a bit of a simplification but this is how it happens. …….

By the way, you should have caught this in the collaborative stage of design. Opps! Some companies still use “Over The Wall’” design.  Shame on them. as an example.…..


.57*1.38+.25*1.38+.218=1.35 in2 *1500/25.4=79.7 in3/.29lb=23.12lb there about.

So we are using .052 ER70-S6 hard wire at 375 ipm wfs, 45 cfph 75/25 gas, 400 amp, 28 volt. Lets set the efficiency at 98%. The maximum width of a weld pass is limited to .56 inch by the applicable code so we are looking at 25+ passes.

23.12/8.4=2.75 hours to make this weld.

2.75 * $75.00 SVC= $206.00 labor

23.12 * 1.02=23.56 lb wire @ $2.00 lb = $46.17

Gas = $56.00          206.00+46.17+56.00=308.17 per weld.

4 welds per unit = 1232.68.  There will be crane time and setup also.