October 2007 Edition
SPOTLIGHT: WELDING
'Rock Stars' Get the Welding Equipment They Deserve
Pulling a company out of bankruptcy meant increasing efficiencies and providing workers with the right equipment
Sfi increased welding from 35 parts a day to 100
Sometimes it takes an odyssey through failure to find success. Sfi of Tennessee LLC went through bankruptcy before gaining success. Today it has customers such as UPS, MTD, Caterpillar, FedEx, International, General Motors, Case New Holland, and Black & Decker.
Sfi is a steel and aluminum fabricator headquartered in Memphis, TN, with a second plant in Conway, AR. The firm manufactures industrial equipment components and subassemblies ranging from locomotive oil pans to crane outriggers.
The company fabricates more than 350 custom products from stainless and carbon steels and aluminum.
Sfi increased welding from 35 parts a day to 100
As a testament to its success, the company has had double-digit growth in recent years. It recently landed a $100 million contract with JLG to make components for the company's lift cranes.
In the past, more than 80 percent of the Sfi's business was in the tractor and trailer industry, making the company's success and profitability susceptible to the sector's stability. After an economic downturn, it declared bankruptcy and was purchased in 2002 by the Lerman family. They invested approximately $40 million to rebuild the company and upgrade its facilities.
In 2005, the family hired Greg Langston as president, an industry veteran with 28 years of experience.
Today, the 50-year-old firm has diversified into other markets, including construction, mining, agriculture, and recreation, keeping Sfi on schedule to double its business in the next five years.
A factor in the company's success was re-engineering its culture, focus, and facilities. Sfi, which has the ability to cut, stamp, form, bend, and weld steel and aluminum components, examined each step of its operations. It adopted lean manufacturing and continuous improvement into its culture.
During the overhaul, management determined the welding operations at its Memphis plant needed updating.
Welders Are the "Rock Stars"
Sfi welders needed equipment flexible enough for the variety
of jobs they do
"Greg considers our welders to be the 'rock stars' of our shop," William Jacobi, Sfi manufacturing engineering manager, said. "He understands the critical role they play and wanted to make sure they were working with the best technology in the best environment."
Upgrades would require a major investment of time, money, and resources, Jacobi met with welding equipment manufacturers and invited two companies to install equipment on the shop floor for a side-by-side, real-world test. After a six-month trial on a variety of projects, Sfi chose and purchased 119 Lincoln Electric Power Wave 355M and 455M inverter power sources. Sfi also installed a Lincoln Power Feed 10M wire feeder for each Power Wave machine.
Sfi required Lincoln to serve a larger role than supplying new equipment. The company used Lincoln as an advisor for welding operations redesign, including equipment, welding wire, processes, welding curtains, floor coating, uniforms, personal protection equipment, lighting, and even paint color.
Jacobi said improvements were solidified at each level of the organization – particularly on the shop floor.
Two-Year Payback
After using the Lincoln equipment for more than a year, Sfi's welders have seen a consistent 15 percent productivity gain.
"Since we're a job shop and manage upwards of 300 different projects a year, the jobs on the floor vary from day to day," Jacobi said. "A welder can work on a school bus bumper one day and a locomotive oil pan the next. With the Lincoln systems in place, we've seen an increase in productivity. This allowed us to take on more projects. Based on current analysis, these machine' will pay for themselves within two years."
Jacobi said the Power Wave machines' versatility contributed to gains in productivity. The 455M handles robotic, hard automation, and semiautomatic applications and offers a range of welding options: MIG, pulsed, STT, and flux-cored.
"In our job shop environment, we require both our welders and equipment to multitask – robotic and manual welding require a variety of processes – submerged, MIG, TIG. It all depends on the job and its requirements," Jacobi said. "The new machines give us the versatility to produce the high-quality products."
Less Spatter; Less Rework
Sfi's welders have nearly eliminated spatter and reduced grinding and rework. Welders have more control over the welding processes with the new machines. They can control burnback time, crater time, and start time, all of which result in a better-quality weld. Welding improvements contributed to the company's productivity increase and faster turnaround time on projects. On particular jobs, Sfi increased welding from 35 parts a day to 100.
Sfi is also using Lincoln's Production Monitoring software, which works in tandem with the Power Wave machines. The software networks the welding equipment. Welding machine data can be viewed by managers to monitor production tasks, set weld limits and tolerances, and track consumable inventory. It also logs welding machine faults for diagnostic troubleshooting locally or from a remote location.
The software let management see a number of welders experienced large periods of downtime. These periods represented time the welders waited for materials or worked on other tasks. The software let Sfi identify and correct this problem, including improving the design of its flow of materials between stations.
The Lincoln Electric Co.
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TIG Welders Help Prevent Burn-Through
Syncrowave 250 DX and 350 LX feature low-end DC TIG arc starting capabilities that help prevent burn-through when welding thin metal. While use of 1/6" or smaller diameter tungsten electrode is recommended for low-amperage arc starts or welding thin materials, the power source's arc-starting circuit also provides positive arc starts with 3/32", 5/32", and 1/8" diameter tungsten. Other features include the Coolmate 3X cooler, compatible with any torch.
Miller Electric Mfg. Co., Appleton, WI
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Mobile Welding Table Features Portability
The Nomad Economy Welding Table, at 46 lb, features a 30"×20" steel tabletop that tilts to horizontal, 30°, and folded positions. Three 1.1" slots let clamps be inserted at any point, so users can fully use the entire tabletop. Two retractable, perpendicular steel guide rails can be used as guides, stops, or as clamping edges. For portability, the table includes two casters and pull handle. Valtra, Inc./Good Hand, Inc., Pico Rivera, CA
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Welders Have Gas Control on Handle
Available in five models, the handheld WP-26 series is manufactured with heavy-duty copper materials and rated to 200-amp DC or 150-amp AC at 60 percent duty cycle. An optional gas control valve on the handle lets welders tune in gas flow, while the optional flexible neck adjusts to any angle. Able to accept tungsten electrodes from 0.020" to 5/32", continuous-duty products are also available with a pencil-style torch for confined joints or automated applications. Weldcraft, Burbank, CA
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Ultrasonic Welder for Non-ferrous Metals
Delivering up to 800 W of ultrasonic energy, the 40 kHz Sonic Weld 4010 is suited for non-ferrous metal-joining applications, such as welding battery components or small gauge electrical wires and terminals. Measuring 4"×5"×12", unit has 1/2 wave reach of 12mm and full wave reach of 115mm. Total travel of actuator is 25mm. Components are presented between the horn and anvil for manual or automated welding. Sonic Tool Company, Milford, CT
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Flux-Cored Wires Offer a Range of Operating Parameters
Dual Shield X-Series provides welders with high deposition rates, fast travel speeds, flat bead profile, limited spatter, and slag removal. It includes wires for use with CO2 or mixed gases, and flat, horizontal, and all-position welding. Wires meet requirements for multiple weld procedures ranging from general fabrication to critical welding applications, and can be used in civil construction and ship building. ESAB Welding & Cutting Products, Florence, SC
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