Benefits of Industry 4.0 for Welding

Industry 4.0, as well as concepts such as the smart factory and digital transformation, present myriad opportunities for welders and fabricators. Industry 4.0 encompasses the rapid technological change that is disrupting businesses across all industries. Advances in communication technologies, devices connected to the internet and data analytics are occurring at a much faster pace than at any other time in history. With the proliferation of smart sensors and the resultant data, welders and fabricators are now able to access insights that have helped to optimise operations and improve efficiencies.

Improvements in Efficiency and Productivity

Industry 4.0 and advanced welding technology is already helping welders and fabricators improve their efficiency and productivity. More and more, to ensure their global competitiveness, businesses are investigating ways to save money and reduce their overheads. The best way to do so is by undertaking operational efficiency improvements that help reduce or eliminate redundancies, errors, bottlenecks and waste.

Welding 4.0 and advanced welding technology play an essential role in creating lean manufacturing processes. The right type of technology can help eliminate workflow delays and duplications and accelerate entire processes through the automation of individual tasks.

Superior Quality and Repeatability

Industry 4.0 production processes are proven to deliver superior quality outcomes and higher repeatability. Any process that improves weld quality and repeatability is worthwhile. Welding is not just a commodity, or a simple, straightforward process. When welds fail, the results can be disastrous. A poor quality weld can be hugely expensive, and can cause massive damage, injuries, and even fatalities.

Better Conditions for Welders

Technological innovations allow businesses to make better use of human skill and innovation, with machines taking over mundane tasks so that employees can focus on critical thinking, quality and creativity. This opens up new opportunities for businesses to improve and optimise their operations.

It can also result in other, more indirect, payoffs. For instance, using a plasma welding machine or a Microsoft HoloLens, or programming a robot, can be more interesting than traditional MIG or TIG welding. Several Weld Australia members that have invested in advanced technology have reported marked improvements in recruiting, training and retaining staff long-term as a direct result.

In addition, advanced technology is helping to make welding a far safer profession. For instance, the use of robots and co-bots (particularly in confined spaces) helps to remove welders from immediate exposure to welding fumes, ultraviolent radiation, heat and sparks.

With advancements in robotics technology, and the likelihood of increased industry uptake, the issue of welder employment rates is inevitably raised. Media frequently reports that the more robots we use, the less jobs there are available. This is rubbish. Robots automate processes, making these processes more efficient, thereby generating even more work.

Real World Examples

SMW Group

SMW Group in Queensland has automated their welding repair processes. The automation of welding repairs for mining industry dragline buckets had been dubbed impossible due to the size and geometry of the equipment, as well as the damage, distortion and uneven wear of components. However, utilising advanced laser seam tracking, adaptive welding software, and a new generation welding system, BOC and RTA built and installed a highly successful robot welding package. SMW has reduced its welding time by between 70% and 90%. It has also reduced overall production costs, improved safety, quality and reporting, and broadened its capabilities.

Welding 4.0 Training

Advanced technology is even having an impact on welder training. Increasingly, old-school training techniques are being complemented by innovative teaching methods that rely on augmented and virtual reality systems.

Augmented and virtual reality training systems are student-focused, allowing individual students to progress at their own pace. Welding apprentices learn and understand welding procedures and techniques through a more interactive training method, gaining hands-on experience in a controlled, safe environment. With zero risks involved, apprentices can respond to realistic scenarios without pressure or fear of injury. Augmented and virtual reality training is enabling future welders to acquire the skills and the self-confidence they need before moving into real-world workshops.

This type of technology is a key feature of Weld Australia’s national network of Advanced Welder Training Centres, which rely on Seabery’s Soldamatic augmented reality welding simulators. The Soldamatic simulators are able to certify 34% more welders in 56% less time, saving up to 68% on the overall cost of welder training. In addition, Soldamatic increases the time on arc by three to five times, and enables training institutes to educate four times more students while maintaining their existing lab infrastructure.

The Future of Welding

Increasingly, Industry 4.0 methodologies, automation, robotics, co-bots and a raft of other advanced welding technology is becoming a critical factor in the success of globally competitive welders and fabricators.

A failure to invest in advanced welding technology could quickly become a failure to invest in the future of your business. After all, as the saying goes, ‘You can’t do today’s job with yesterday’s methods and expect to be in business tomorrow’.

Further Information

If you would like more information, please feel free to contact us.