 Trial 3
Tier One Supplier September 22nd to October 3rd, 2003 MIG TIP TRIAL / COMPARISION
This trial was conducted for 2 weeks on 9 robots running 1 to 3 shifts each. Each tip style ran for 1 week or 5 production days. The wire used was S6 solid wire .045 at 200 - 255 Amps and 20 - 22 Volts. The power supply was Lincoln and the gas mixture was 8% Carbon Dioxide to 92 % Argon.
The 2 tips tested were Superior Consumables T403-1-43S - CuAg alloy .051 ID (SC) with a Tregaskiss® style T404-3 diffuser and our current taper lock tip 403-20-1.0 regular alloy .050 ID (TG) with a Tregaskiss®
404-30 diffuser.
The following is the five-day data collections of tip failures. The operators were told to run all tips to failure or to a poor weld condition and record all data.
| DATE
|
9/22
SC |
9/23
SC |
9/24
SC |
9/25
SC |
9/26
SC |
Tips
Used |
9/29
TG |
9/30
TG |
10/1
TG |
10/2
TG |
10/3
TG |
Tips used |
| ST40 ROBOT A |
0 |
0 |
1 |
0 |
0 |
1 |
0 |
2 |
2 |
1 |
2 |
7 |
| ST40 ROBOT B |
0 |
0 |
1 |
0 |
0 |
1 |
1 |
0 |
1 |
1 |
1 |
4 |
| ST50 ROBOT A |
0 |
0 |
1 |
0 |
0 |
1 |
0 |
0 |
0 |
0 |
1 |
1 |
| ST50 ROBOT B |
0 |
1 |
1 |
0 |
0 |
2 |
0 |
0 |
1 |
1 |
0 |
2 |
| ST60 ROBOT A |
0 |
1 |
1 |
1 |
0 |
3 |
0 |
0 |
2 |
1 |
1 |
4 |
| ST60 ROBOT B |
0 |
2 |
1 |
1 |
0 |
4 |
1 |
0 |
2 |
2 |
0 |
5 |
| ST70 ROBOT A |
0 |
3 |
0 |
0 |
1 |
4 |
0 |
1 |
0 |
1 |
0 |
2 |
| ST70 ROBOT B |
1 |
0 |
0 |
1 |
1 |
3 |
2 |
0 |
0 |
1 |
0 |
3 |
| ST70 ROBOT C |
0 |
1 |
1 |
0 |
0 |
2 |
2 |
3 |
3 |
3 |
1 |
12 |
| SHIFTS |
1 |
3 |
2 |
2 |
2 |
21 |
1 |
2 |
2 |
2 |
1 |
40 |
Summary:
The Superior Consumable tip (SC) produced a total of 21 tip failures on a run of 10 shifts. The Tregaskiss® Tough Lock (TG) produced a total of 41 tip failures on a run of 8 shifts. This shows very significant increase in line efficiency with a potential 50% reduction in tip usage.
S.M - Production Manager
Trial 4
VARI FORM – TIP TRIAL 40+ ROBOTS November 4 – 15, 2002
This trial was conducted for 2 week on 4 robots running 2 shifts. Each tips style was ran for 1 week or 5 production days. The wire used was S6 solid wire .035 at 260 Amps, 24 Volts and S6 solid wire .045 at 255 Amps and 22 Volts. The power supply was Panasonic and the gas mixture was 8% Carbon Dioxide to 92 % Argon.
The 2 tips tested were Superior Consumables CuAg alloy (SC) with a Tregaskiss® 404-3 diffuser and our current taper lock tip (TG) with a Tregaskiss® 404-30 diffuser.
The following is the five-day data collections of tip failures. The first tips were installed on day 1 at the beginning of the shift and are not shown:
| DAY |
CELL |
CELL |
CELL |
CELL |
CELL |
CELL |
CELL |
CELL |
| |
1-1 SC |
1-1 TG |
1-2 SC |
1-2 TG |
2-1 SC |
2-1 TG |
2-2 SC |
2-2 TG |
| 1 |
1 |
0 |
0 |
0 |
1 |
0 |
1 |
2 |
| 2 |
1 |
1 |
0 |
1 |
0 |
2 |
1 |
1 |
| 3 |
0 |
0 |
0 |
1 |
0 |
2 |
1 |
0 |
| 4 |
0 |
1 |
0 |
1 |
0 |
1 |
2 |
0 |
| 5 |
0 |
2 |
0 |
0 |
1 |
1 |
1 |
0 |
| TOTAL |
2 |
4 |
0 |
3 |
2 |
6 |
6 |
3 |
Summary: The Superior Consumable tip (SC) produced a total of 10 tip failures on a run of 12,000 parts. Including the 4 initial tips, each Superior Consumables welding tip averaged 857 parts.
The existing tip (TG) produced a total of 16 tip failures on a run of 10,600 parts. Including the 4 initial tips, each welding tip from out existing supplier averaged 530 parts.
GH -Manufacturing Engineering |
