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Aluminum Trailer Mfg. Cuts Downtime in Half...
- Manufacturer converts 30-arc fleet
- One contact tip lasts three days vs. 10 tips per day previously
- Better arc starts, better weld quality, less spatter, less rework and faster tip change-outs
Customer Testimonial
“Day in and day out, Bernard Centerfire tips and nozzles hold up to our demands for quality and help us increase production.”
— Tony Hackney, Plant Manager, Cimarron Trailers, Inc.
Application
MIG welding custom-built aluminum horse, stock and cargo trailers that are well engineered and well constructed at extremely competitive prices
Key Business Issue
Lost production time resulting from changing out contact tips and nozzles an average time of three times per shift, per machine.
Challenge
- Introducing welding operators to MIG consumables with a unique design and helping them accept and understand the benefits of this design.
- Understanding that although premium consumables cost more up front, they lower overall welding cost through improved productivity
Previous System & Process
- Standard MIG consumables with a threaded contact tip and slip-on nozzle.
New Solution
- Bernard Centerfire consumables
- Adaptor so existing gun can accept Centerfire consumables
Results
- Tip change-out time reduce 50%. The unique non-threaded design of Centerfire contact tips makes changing tips extremely easy, even when the wire burns back to the tip. Further, tip use decreased significantly, lowering overall cost for consumables.
- Better weld quality. Operators immediately noticed smoother, more positive arc starts with much less “popping” and associated spatter. Further, Centerfire improved gas coverage and eliminated the black soot associated with poor gas coverage on aluminum.
- Less clean up and rework. Improved weld quality freed operators for other activities.
