“Plastic Welding Classes take away from production time”?
“I cannot spare that many people to be away from their work stations
for 2-3-4 days.”
“In-House training is great, but we do not have enough space or classroom to complete the training?”
I get comments like that on a regular basis and understand where the Management of these companies are coming from, I have been in their shoes. OK, what is the alternative?
Working with various customers, especially those with Quality Assurance/Quality Control programs, want me to come on site and work with their welders and minimally affect daily productivity. And the solution is quite simple, I travel to you the customer, you have an abundance of work, yet you want to ensure that the product you are producing meets with your QA/QC program and that of your customer.
Following are a couple of examples, (I will not use any customer’s name.) I have a few NDA’s that I must live by.
A. Most shops have from 4-16 welders working at their individual work stations. The experience level is anywhere from a few weeks to a few decades. I review the company’s QA/QC program and that of their customer, if comments are necessary, I make them either in writing or we do this as a joint review meeting with notes taken. I take this information to the welders, usually through the Shop Foreman or Superintendent or Shop Engineer. I will go from workstation to workstation and explain who I am and what I will be doing over a given period. I will look over the welding equipment, the weld preparation equipment, the cleanliness/neatness of the work area, measure temperatures etc. I will ask questions about what they are doing, offer suggestions that might improve what they are doing, and monitor the drawings, weld sketches, material to be welded, welding rod, actual preparation of the weld and the performance of the hands-on weld. If I have any questions or comments, I will bring them up while I am at the workstation. Depending upon the experience of the welder this may be one hour or whatever time it takes especially for the new welder. Prior to my leaving each individual workstation I will hand the welder 4 pieces of plastic cut with single “V” and or “X”, of each type of plastic the welder usually welds, along with a blank” Weld Record” for each weld sample welded. The completed samples can be accomplished during breaks or in between welds or before or after shift. I usually want the samples with the Weld Record turned in at least 24 hours before I leave, to give each weld time to acclimate and complete the fusion/bonding process.
1. This process has worked out very well especially with companies that have a large backlog, or an urgent project in process.
2. I will spend time with each welder throughout my stay and am always available before and after shift changes to handle individual or group discussions.
3. Upon completion of the weld samples I prepare each sample for testing. I will remove the excess weld bead, round all corners, make sure there are no “nicks or notches” or saw kerf marks on the sample. I make sure all samples are cut to the proper width and identified with the welder name or number and tested with a field bend tester. Results are noted, the weld evaluated, and noted on the Weld Record.
4. Either before all the training/observation/monitoring we will have approx. an hour or two of formal discussion/lecture time. This is good for everyone, it is a reminder for the welder with decades of welding experience, and for the newcomer we will individually or as a group have a more formal class.
B. Some shops work multiple or split shifts, or have a considerable number of welders, we may then do the training in groups, and actually shut down productivity for an hour or two of lecture/class session, then we will revert back to doing either class welding of samples or the individual welders go to their work stations and we proceed as listed above.
The emphasis is that we want all the welders to have confidence in what they are doing, we want supervision to know that they are trained (Weld Record), and management to know that trained welders are at work. And the sales force or sales Engineers or design Engineers can have something tangible to show a new or old customer, that the company has a program that works and is reviewed on an annual basis by an independent party.
C. This whole program can be modified to fit each company’s needs, I am flexible, I have had two man classes and 20 person classes, I have worked in nice climate controlled shops to the North Slope of Alaska to the sandy and windy out of doors in Kuwait or the deserts of Nicaragua or Very Modern and Not so Modern shops of South East Asia.
I am available for you, your welders, your equipment needs and equipment service.
Give me a call or fill out the contact form here on the website, let us talk.
Contact Information for Larry
1010 Vermont Ave.
The Villages, FL 32159
Approximate Cost estimate:
Travel $1/mile one way from zip code 32159
Per Diem: $50/day
Hotels: I usually stay at Hampton Inn’s or Garden Inn’s (cost estimate will be provided)
Training/Consulting Days On-Site $1250/day
“Certificate of Training” and Training extract $30/welder. (Supervision, QA/QC personnel, Engineers are not charged.)
I will provide a training extract based upon your training needs or your customers QA/QC documents. I will provide the non-destructive and destructive testing equipment, additional welding equipment, Hot Air/Gas, and extrusion welding equipment.
I usually drive to most Company sites except the west coast, I will fly to the nearest Airport and use a rental car. I will also ship my equipment to your facility. (If I fly the overall cost of the shipping, flight and shuttle service, rental car etc. is usually about the same as the $1/mile. course information