welding

2. INTRODUCTION TO WELDING
WELDING: Welding is the process of joining of 2 or more metals with application
of heat, with or without filler material and with or without pressure.
CLASSIFICATION OF WELDING.:
SPOT
WELDING
Co2 / MAG
WELDING
WELDING
FUSION
WELDING
PRESSURE
WELDING
BRAZING
GAS
WELDING
ARC WELDING
SPECIAL
WELD
GAS PRESSURE
WELDING
RESISTENCE
WELD
FRICTION
WELDING
HARD BRAZING
SOFT
BRAZING
NON CONSUMABLE
ELETRODE TYPE
TIG ARC
WELDING
PLASMA ARC
WELDING
MIG ARC
WELDING
SUBMERGED
ARC WELDING
SHIELDE METAL
ARC WELDING
SELF SHIELDED
ARC WELDING
CONSUMABLE
ELETRODE TYPE

3. CO2 WELDING INTRODUCTION.
CO2 Welding is an electric arc welding process where the heat for welding is
produced by an arc between a continuously fed consumable filler rod
electrode and the work.
3 Main essentials of Co2 welding are:
1. Power
2. Filler material
3. Shielding agent.
1. POWER: Power is required to generate arc, arc generates heat.
Required welding power is
for 1.2 mm dia wire = 24V and 220A
for 0.8 mm dia wire = 16 V and 160 A
2. FILLER MATERIAL: Filler material is used to fill the gaps and to give extra
strength. Filler material used is copper coated mild steel( CCMS).
Coating is done to avoide rust and for electrical conductivity. 1.2 mm dia
wire is used in frame line( thicker parts) and 0.8 dia wire used in body shop
( Thinner parts).

4. 3. SHIELDING AGENT: Shielding agent used to prevent oxidation.
Shielding agent used in TKM is mixture of Argon + Co2 ( 80% + 20%)
Volume of ACM gas for welding is 12 to 14 LPM.
CO2 WELDING DEFECTS.:
1. BLOW HOLE
2. UNDER CUT
3. OVERLAP

5. 4. LESS PENETRTION
5. IN SUFFICIENT BEAD LENGTH
6. EDGE BURN
7. HOLE

6. 8. BEAD WIDTH LESS
9. BEAD DISCONTINUATION
10. BEAD MISPOSITION
11. BEAD MISS

7. SPOT WELDING INTRODUCTION
Spot welding is a Resistence welding in which two or more joining materials
hold under the pressure and passing the current through at a point.
SPOT WELDING REQUIREMENT:
1. Power( Current and Voltage): Power is required to generate the heat due
to resistance by the joining materials under the pressure.
2. Air: Air is required to operate the cylinder and by gun arms to hold the
joining materials under pressure.
3. Water: Water is required to cool the heat generated in transformer,
kickless cable , gun arms and tip by absorbing the heat.

8. Advantages of Spot Welding :
1. Low Cost,
2. High speed of Welding,
3. Dependability,
4. Less skilled worker will do,
5. More general elimination of Warping or distortion of Parts,
6. High uniformity of products,
7. Operation may be made automatic or semi automatic, and
8. No edge preparation is needed.

12. SPOT HANARE
SPOT HOLE
PIN HOLE
SPOT BURR
SPOT PITCH NG
SPOT POSITION
SPOT MISS
HALF SPOT

14. 1) CONFIRMATION OF TIP CHANGE AT SHIFT START
2) DO TIP CHANGE AT REGULAR INTERVALS
3) CHECK FOR GAP B/W TIP TO TIP
4) CONFIRM GUN TAPE INSULATION ON THE GUN ARM
5) DO NOT DEVIATE FROM THE STD WORK PROCEDURE
6) CHECK FOR GUN TIP OFFSET
7) CHECK FOR ANY DUST OR OIL PRESENCE ON THE
PANEL
8)CHECK THE CONDITION OF GUIDES & TEMPLATES
9) IF ANY GAP FOUND B/W PANELS TAP IT BY USING
HAMMER & WELD
10) GENCHI OBSERVATION SHOULD BE DONE FOR ANY
DEFECT FEED BACK
TO
AVOID
THIS 8
SPOT
WELDIN
G
DEFECTS
PLEASE
FOLLOW
THESE
STEPS

15. SAFETY

18. QUALITY

19. PURPOSE:
To maser the accuracy of the weld part as per standard.
Frame weld accuracy standard was 95%
Measuring Method: 1) Surface 2) Inclined
1 2
3
1
3
2
2 2
1 2
3
2
35
4
HOLE SQUARE
1
3
2
1
2
3
4
5
6
1
SURFACE INCLINED

20. Most Important safety point in process, Customer safety point of view extra care
taken in to this process.

22. 5 Pin hole
Pin hole occurs
at crater during
solidification
*Improper gas
pressure
*Surface having oil or
dust
*Arc end point pause
time NG.
Gas pressure should be 1.5~2.0bar
Pause time should be 0.5~0.8sec
4 Spatter
Small atoms like
structure
accumulated
around the bead
*High Current
*High speed
*More wire gap.
Speed should be as per standard
( Refer standards provided in teach
pendant)
Wire gap should be 15~17 mm
3 Blow Hole
Holes in the
Bead
*Abnormal gas flow
*Gas mixture NG
*Moisture on wire or
panel
*More gap between tip
& panel
*External air like
(cylinder leak, fan)
Gas flow should be 18~22 Lpm
Gas Mixture argon 80% Co2 20%
Panel & Wire should be free from
dust & oil.
Wire gap should be 15~17mm
External Air should not be there.
Metal was not
filled at bead toe
*High Current
*High Voltage
*High Speed
*Torch Angle NG
*Less Wire gap
*Panel gap
*Bead width more
*Aim point NG
*Welding Conditions should be as per
Standards ( Refer weld condition
sheet)
*Angle should be 45~60 deg
*Wire gap should be 15~17mm.
*Weaving option to be used if wider
bead is required
At the end of
bead metal not
fused, or Bead
extended over
the panel
*Low current
*Low Voltage
*Low Speed
*Torch Angle
*Less gap between
wire & tip
*Welding Conditions should be as per
Standards
*Angle should be 45~60 deg
*Wire gap should be 15~17mm
1 Under Cut
2 Overlap
Arc Quality Defects - Details
SL NO DEFECT TYPE ILLUSTRATION REASONSMEANING STANDARDS

23. 5 Pin hole
Pin hole occurs
at crater during
solidification
*Improper gas
pressure
*Surface having oil or
dust
*Arc end point pause
Gas pressure should be 1.5~2.0bar
Pause time should be 0.5~0.8sec
4 Spatter
Small atoms like
structure
accumulated
around the bead
*High Current
*High speed
*More wire gap.
Speed should be as per standard
( Refer standards provided in teach
pendant)
Wire gap should be 15~17 mm
3 Blow Hole
Holes in the
Bead
*Abnormal gas flow
*Gas mixture NG
*Moisture on wire or
panel
*More gap between tip
& panel
*External air like
(cylinder leak, fan)
Gas flow should be 18~22 Lpm
Gas Mixture argon 80% Co2 20%
Panel & Wire should be free from
dust & oil.
Wire gap should be 15~17mm
External Air should not be there.
Metal was not
filled at bead toe
*High Current
*High Voltage
*High Speed
*Torch Angle NG
*Less Wire gap
*Panel gap
*Bead width more
*Aim point NG
*Welding Conditions should be as per
Standards ( Refer weld condition
sheet)
*Angle should be 45~60 deg
*Wire gap should be 15~17mm.
*Weaving option to be used if wider
bead is required
At the end of
bead metal not
fused, or Bead
extended over
the panel
*Low current
*Low Voltage
*Low Speed
*Torch Angle
*Less gap between
wire & tip
*Welding Conditions should be as per
Standards
*Angle should be 45~60 deg
*Wire gap should be 15~17mm
1 Under Cut
2 Overlap
Arc Quality Defects - Details
SL NO DEFECT TYPE ILLUSTRATION REASONSMEANING STANDARDS
10 Throw hole Hole in the bead
*Current is too high
*Torch angle NG
*Less wire gap.
Current as per standard
Teach angle 45~60deg
Wire gap between job to tip
15~17mm
9 Leg Length
Distance of the
bead is too
length with less
penetration
*Current is too high
*Torch angle NG
*More wire gap.
Current as per standard
Teach angle 45~60deg
Wire gap between job to tip
15~17mm
8 Throat length
Shortest
distance of bead
from the route
*Current is too high
*Torch angle NG
*More wire gap.
Current as per standard
Teach angle 45~60deg
Wire gap between job to tip
15~17mm
7 Bead uneven shape
Bead width
changing from
point to point
*Wire gap getting
changed from point to
point
*Wire movement NG
*Fluctuation in input
Voltage.
Wire gap between job to tip
15~17mm Wire pulling at
tip end should be <2kg Input
power variation +/-10%
6 Bead crack
Bead cracked
along & across
*Current is too high
*Panel gap is more
*Torch angle NG
*Foreign material mix
with molten metal.
Current as per standard
Panel gap<1.0mm
Teach angle 45~60deg
No dust, dirt on molten metal
solidification
dust
*Arc end point pause
time NG.
Pause time should be 0.5~0.8sec
Leg
Throat

24. Spot Quality Defects - Details
SL NO DEFECT TYPE ILLUSTRATION MEANING REASONS STANDARDS
1
Expulsion at Weld
Interface
Flash coming in
b/w sheet metals
in welding
* Short Squeeze Time
* Low Weld Force
* Dirty - Scaley
Material
* Poor panels
matching
* Weld conditions shold be as per
Std.
* Panels should be free of dirt.
* Gap b/w panels should be 0.3mm
2
Surface Expulsion /
Flash / Burr
Flash coming in
b/w panel &
electrode in
welding
* Short Squeeze Time
* Low Weld Time
* Low Hold Time
* Low Weld Force
* High Weld Current
* Dirty - Scaley
Material
*Welding Conditions should be as per
Standards
* Gap b/w panels should be 0.3mm
* Panels should be free from dirt.
3 Low Weld Strength
Spot Hanare /
Panels
seperation after
Welding.
* Short Weld Time
* Small / Large
Electrode face area.
* Low Weld Force
* High Weld Current
* Dirty panel surfaces
* Shunting
*Welding Conditions should be as per
Standards
* Panels should be free from dirt.
4
Internal Cracks in
Nugget & Cracks In
Parent Material
Discontinuities
within the weld
nugget and/or
surrounding area
* Hold time short
* Incorrect electrode
dressing
* Insufficient Cooling
* Squeeze time short
* Weld current high
* Weld force low
* Dirty material
*Welding Conditions should be as per
Standards
* Panels should be free from dirt.
5 Indentation
Spot weld that
fractures the
surrounding
metal
* Hold time long
* Incorrect electrode
dressing
* High Weld Current
* High Weld Current
*Welding Conditions should be as per
Standards

25. Spot Quality Defects - Details
SL NO DEFECT TYPE ILLUSTRATION MEANING REASONS STANDARDS
1
Expulsion at Weld
Interface
Flash coming in
b/w sheet metals
in welding
* Short Squeeze Time
* Low Weld Force
* Dirty - Scaley
Material
* Poor panels
matching
* Weld conditions shold be as per
Std.
* Panels should be free of dirt.
* Gap b/w panels should be 0.3mm
2
Surface Expulsion /
Flash / Burr
Flash coming in
b/w panel &
electrode in
welding
* Short Squeeze Time
* Low Weld Time
* Low Hold Time
* Low Weld Force
* High Weld Current
* Dirty - Scaley
Material
*Welding Conditions should be as per
Standards
* Gap b/w panels should be 0.3mm
* Panels should be free from dirt.
3 Low Weld Strength
Spot Hanare /
Panels
seperation after
Welding.
* Short Weld Time
* Small / Large
Electrode face area.
* Low Weld Force
* High Weld Current
* Dirty panel surfaces
* Shunting
*Welding Conditions should be as per
Standards
* Panels should be free from dirt.
4
Internal Cracks in
Nugget & Cracks In
Parent Material
Discontinuities
within the weld
nugget and/or
surrounding area
* Hold time short
* Incorrect electrode
dressing
* Insufficient Cooling
* Squeeze time short
* Weld current high
* Weld force low
* Dirty material
*Welding Conditions should be as per
Standards
* Panels should be free from dirt.
surrounding
metal
* High Weld Current
* High Weld Current
Standards
6 Pin hole
forceful ejection
of molten metal
from the weld
*Hold time short
* Incorrect electrode
dressing
* Squeeze time short
* Weld current high
* Weld force low
* Insufficient Cooling
* Dirty material
*Welding Conditions should be as per
Standards
* Panels should be free from dirt.
7
Internal Porosity /
Blow hole
Discontinuities
within the weld
nugget and/or
surrounding area
*Hold time short
* Incorrect electrode
dressing
* Squeeze time short
* Weld current high
* Weld force low
* Insufficient Cooling
* Dirty material
*Welding Conditions should be as per
Standards
* Panels should be free from dirt.
8
Weld Nugget
Displaced
Weld nugget shift
from centre
* Electrode
Missalignment
* Poor matchup of
panels
* Electrode alignment should be
proper
9
Half Spot / Non
circular weld
Discontinuities in
the weld nugget
* Incorrect electrode
dressing
* Electrode
Missalignment
* Electrode alignment should be
proper
* Gap b/w panels should be 0.3mm

26. CUT CHECK

35. POKAYOKE

36. Visualisation pokayoke done to check how many wire is there in the spool. Helps in
knowing when we need to change wire and minimises line stop time.

37. Machine covered with transparent sheet to avoide spatter hitting to operators face. Safety
of the operator is ensured with this..

38. Locating hole for the part is made to avoide nut position change.

39. Flange bend parts can cause the whole assy scrap. This will help in determining the NG
parts and prevent quality problem..

40. When part is clamped , if they lift the part there are chances of whole jig falling on TM.
Pokayoke done in clamp such that if the part is unclamped then only part can be lifted.

41. PRODUCTION

42. 3.11 KYT :
KIKON YOCHI TRAINING is “Tool to prevent the accident by sharing information
on potential accident points & safe way of working”.
3. PRODUCTION.
3.1 DAILY MANAGEMENT
Practice every shift start after meeting to highlight safety point

43. 3.12 Assignment Board:
Assignment Board gives overall view of group / process.
Assignment board contains –
1> Layout of process & TM’s position.
2> GL’s activity.
3> Attendance Status.
4> Skill Matrix.
5> Yamazumi chart.
6> 4M Change point.
3. PRODUCTION.

44. Date & Shift Yamazumi
GL Activity Change Point
Attendance
Status

45. 3.2 Standardized Work:
SW is effective utilization of man, material & machine
SW Contains two major things –
1> Three Elements of Standardized Work
2> Charts and sheets for Standardized Work
3. PRODUCTION.
Purpose:
It’s help for checking the members movement whether member follow the SW or not.

46. 3.21 Elements of Standardized Work:
3. PRODUCTION.
A standard time with which one output has to be made.
Work sequence a TM should follow to complete the Operation
Number of in process stock which should be kept to enable TMs to follow
the work sequence seamlessly.
1.TACT TIME
2.STD STOCK
3. WORK SEQUENCE

47. 3.22 Charts & Sheets for Standardized Work:
3. PRODUCTION.
PRODUCTION
CAPACITY SHEET
1
SEQUENCESHEET
2
STANDARDIZED
WORKCHART
4
YAMAZUMI
6
STANDARDIZED
WORKCOMBI
TABLE
5EIS/WIS
3
EIS/WIS
EIS/WIS
EIS/WIS
EIS/WIS

48. 3.3 Tip Management for Spot Welding:
Tip management is very imp to control the Spot Weld Quality of product.
Tip Board:
Tip board is used to control the tips in process. Tips in Tip Board are arranged
in a matrix based on Process & m/c no.
Tip change frequency:
Tip change frequency is set based on process, i.e., Kaku’S’ points, General
points & special cases.
Color code is used for visualization.
1. Black - 01 Hr.
2. Yellow - 02 Hr.
3. Blue - 04 Hr.
4. Green - 08 Hr.
3. PRODUCTION.

49. M/c No.

50. 3.4 Hanare Checking:
Hanare check is Random sample check, & it is done to ensure the Spot Weld
Quality of product.
Hanare Check frequency:
Hanare Check frequency is set based on time for processing the product within
which can be tracked before sending it to next process.
Ex,.
Hanare Check Frequency = 2 hrs
3. PRODUCTION.
WELD SHOP PAINT SHOP
WIP
(10 min)(Processing Time = 2 hrs)

51. LOGISTICS

52. WELD LOGISTICS MAJOR TASKS
1)Overall parts flow system
2)Parts receiving system
3)Parts supply system
WELD LINE
For basic flow consider the below chart
PARTS AND INFORMATION FLOW

53. PARTS RECEIVING AND STORING PREPARATION
• Parts receiving and storing preparation is the logistics from supplier to
receiving dock and receiving dock to store. This is basically comes under
ILCD group
Part receiving and storing can be classified as follows
1. Local Parts receiving & storing system
2. CKD parts receiving & storing system
3. In-house Press parts receiving & storing system
4. Over all receiving system

54. PUNE
BANGALORE
TRANSYSTEM
CROSSDOCK
PUNE
CROSSDOCK
CHENNAI
TRANSYSTEM
TRANSYSTEM
TRANSYSTEM
CHENNAI

55. LOCAL PARTS RECEIVING:
The following activities to be done in local parts receiving
• Supplier truck cycle ,delivery schedule
• Packing style and box qty fixing
• Receiving dock
• Receiving system
The truck cycle and no of trucks for each supplier decision is
taken on the basis of total volume from each supplier and
region and other details . basically local parts project group do
this activity.

56. PACKING STYLE AND BOX QTY FIXING
The packing specification fixing activity is to be decided considering all
aspects like user workability ,handling workability ,truck efficiency, quality.
Plastic Bins.
Since the plastic bins stocked one above other on wooden pallet multiple
sizes from small size to be selected.

57. Special pallet also can be selected for store
We should go for special pallet if
Part can not be accommodate in std pallet
Part quality will get effect if it stored in std pallet
Part handling is not possible in std pallet
Very less qty of parts if std pallet

58. Common thing to be considered in receiving are
All supply movements should be mikara movements that is one movement
with filled boxes and return with empty boxes or dolly.
• Local parts storing
• Local parts usually having returnable packing . Basically the storing is
depends on type of packing. The most suitable type of storing are
• Flow Rack
• Shooters
• On floor storing
• Dolly type storing
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PLASTIC BIN RCV AREA
METAL PALLET SHOOTERS
FLOW RACKS
EMPTY
PALLET
EMPTY BIN

59. FLOW RACK SHOOTER
DOLLY STOREON FLOORING STORE

60. PARTS SUPPLY SYSTEM TO LINE
• Chorokyo supply system
• Pallet/box supply system
• Jundatte supply system
• Minomi supply system
• Jumbiki system
• SPS supply system

61. There are two types of chorokyo systems based on supply system
Fixed time variable qty .
Variable time fixed qty .
In fixed time variable qty supply system the dollies are supplied to line in
fixed time and the qty is varied according to line run
In variable time fixed qty system the dollies/parts supplied with fixed qty
of parts but supply time is variable it is not fixed means cycle time is not
fixed.

62. JUNDATTE SUPPLY SYSTEM
Jundatte supply system is supply of parts production sequence wise.
• This is usually used for big parts like back door panel, side member panel,
seats etc
D
L
X
1
D
L
X
2
S
T
D
D
L
X
3
D
L
X
1
D
L
X
2
S
T
D
S
T
D
D
L
X
3
D
L
X
1
D
L
X
2
S
T
D
STD
DLX3
DLX1
STD
DLX3
DLX1
SEQUENCE
SHEET

63. Minomi supply system
Minomi means box less it is the system of supplying only parts to line.
UN
PA
CK
IN
G
ST
ATI
ON
2
M
0
1
MINOMI
DOLLY
AREA
Supply to
line
Jumbiki supply system
Jumbiki system is same as zundatte system only difference is if
the parts are set sequence wise at supplier end then it is
called Jumbiki.
SPS supply system
SPS supply system SPS means Set Parts Supply this supply is
similer to chorokyo supply system. Here the parts are supplied
in sets of bodies to be produced

64. COST

65. Definition:
Cost is the expense that “a company incurs when making or selling products”
Manufacturing Cost ＋Sales Expense → Total Cost
Advantages:
1. To determine the exact cost of each item
2. To supply information for detection of wastage of material & labor
3. It provides checks on various expenses
4. It helps in budgetary control
5. It is measure for arriving at the efficiency of the whole concern
6. To provide information to certain the selling price of the product
Overall it helps in reducing the total cost of manufacturing

66. 4. COST.
How to Increase Profit?......
Profit (Sales Price Cost) Unit Sales
Profit
(Sales Price)
(Sales Price)
(Sales Price)
Profit
Profit
Cost Cost
Cost
(principal of cost) (Cost Reduction)

67. How to derive Cost?
4. COST.
Gentan-I :
Quantity of material usage, man-hours required, etc. to
manufacture a part.
Rate:
Cost per unit of Gentan-I ( Rs. /kg, Rs./ltr etc.)
Cost = Gentan-I x Rate

68. 4. COST.
Kaizen Thinking Way
Gentan-I
Actual
consumption
Wastage Wastage
Wastage
KAIZEN KAIZEN
Reduce wastage
Gentan-I = Act cons
Do Kaizen to reduce Gentan-I
& Set new Std
1. Eliminate wastage by TPS Tools
2. Standardize everyone’s job & continuously follow S/W
Identify
gap
Cost = Gentan-I x Rate
Std consumption / unit Price
>Localization
>Source change
It is important to grasp cost by Gentan-I & Rate , and to reduce either of them

69. 5R's Applicability Eg Guidelines to Achieve
Reduce
(Minimize wastage &
do Kaizen)
Direct & Indirect Material
Energy
Direct & Indirect Material:
Sealers, Gas, Steel, Paint, C02
wire, Safety gears & other GPS
consumables,
Energy:
LPG, Electricity, Water
Reuse
(Optimum usage)
Indirect Material Safety gears, Tools
Recycle
(Optimum usage)
Indirect Material Safety gears
Refine
(Efficiency up)
Regenerate
(Re-create)
Eliminate
(Muda reduction)
Rejection Parts & components
Rejection
. Follow key point for assy to
avoid rejection
. Immediately inform to
supervisor
for Countermeasure to avoid
rejection
. Ensure built -in quality to avoid
repair / rejection in next
process
Packing Proposals
Ve-Va Proposals
Packing spec change, Excess
part elimiation
Direct & Indirect Material
. Use as per standard
. Follow FIFO method
. Keep Clean working area to
increase maximize safety
gear usage life
Energy
. Switch off lights, fans,
Equipments during
non working hours and
off time
. Avoid air leak points,
(Inform to supervisors)
. Check equipments in your
area to ensure standard
(Pressure, temperature)
How to Achieve the Cost Reduction

70. 4. COST.
Category Description Major Contributors
Direct Material Which goes along with the
vehicle
CO2 wire, Sealer, Brazing rod
Indirect
Material
Materials used for the
production, but it is not a part of
the vehicle
Safety gears, tools, consumables
Eg. Liquid Argon, Safety wears etc.
Energy Electricity, LPG, water and Air
consumed during the production
Electricity, Water, WWT, Compressed Air
Rejection NG parts which are not passed
to the next process
Weld sub assemblies
Maintenance Cost incurred for Regular
maintenance of the E/Q, Dies
etc.
Shop Maint
(Break down, Preventive maint, General)
Labor Working in line & support
activities
Weld Shop Manpower
(TMs, Apprentice, Contract labor etc)
Depreciation Redeemed value of the asset Dies, Jigs, Checking fixtures, Robots etc.
Weld Shop Cost Contributors

71. Questions ?
Any Suggestions…