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Summary and Outline of 

Lean Welding  Manufacturing-Shielding Gas

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Lean Welding Manufacturing Tools

Managing Shielding Gas Use


A precept of Lean Manufacturing  is "Most of the Waste in Manufacturing is Invisible."  That sure fits "Shielding Gas Waste, in More Ways Than One!"

Also, did you know if shielding gas is leaking out of a hose or fitting air and moisture are leaking in!  Sounds strange--it's true.  The reason is defined in our program.

If your into "Lean" than you know "sustainability" is the key to maintain your progress.  We discuss simply ways to have your workforce maintain the waste reduction and quality improvement you'll achieve with our approach.

Note: As a Senior Manager for a welding equipment manufacturer,  participated in a 1 million + dollar improvement program with DeWolff Boberg and Associates, Management Consultants.  They worked closely with the production team and hourly workforce and saved well over the expenditure.  Each of the work teams would report results summaries to the senior management team.  The analytical approach learned and used by many of the hourly workforce was impressive. 

See Background in Lean Techniques

You can save significant $'s in wasted shielding gas and improve weld quality with our,

"Lean Welding Manufacturing Tools."

How? :

Assign your lead welder, welding foreman or welding supervisor the task of measuring gas flow (an inexpensive tool is all that is needed.)  Have them review the information provided in our Lean Welding Manufacturing Tools, Self Study Course.  That will define the maximum shielding gas flow rates they should use.  It will show them why excess shielding gas flow rate pulls air into the shielding gas stream making shielding quality worse not better.  Have them measure flow on all welding machines and discuss desirable flow rates with all welding related employees. 

In addition to excess gas flow surge at the weld start, setting the proper gas flow rate is very important.  Unfortunately welders often follow the adage, " If a little is good more must be better."  Our training material outlines the maximum flow that should be used before air is pulled into the shielding gas stream.  It defines how much draft or wind can be tolerated in MIG welding and why increasing flow beyond defined levels makes shielding worse.

That  person(s) will learn how to check for gas leaks in the delivery system and at the welding torch. They can plot flow rates and detect possible leaks.  They will learn how a 0.035 "wire size" leak in a 50 psi gas pipeline or hose can cost over $14,000/year.  Fixing one leak of that size will payback the cost of the program in a week !!

With a little information from purchasing they can  plot the total shop purchase  of shielding gas each month and divide it by the pounds of wire bought.  Our Lean Welding Manufacturing Tools show a simple way to develop and use a 3 to 6 month rolling average of this ratio to raise a red flag when values increase.  It also provides  benchmark data to compare your rates with industry standards.

They can communicate their findings to all those involved in welding by posting a simple Graphical Chart (Included with the Course) on a Bulletin Board reminding all of why excess gas flow creates problems.  Maintaining a focus on gas usage will help reinforce the waste and poor weld performance that will occur from excessive gas flow rates set by a welder or occurring at the weld start. 

It includes a simple method to use to calculate the actual leak rate in pipelines.  After conducting the 1st test it can be repeated on an ongoing basis in a mater of minutes with just the use of a watch!

Want details of what is included in Lean Welding Manufacturing Tools?

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"Optimizing Shielding Gas Use and Eliminating Waste" WAT LWM-SG

or a basic "Self Study" Program for Welders

"Understanding and Setting MIG Gas Flow Rates" WAT-UFG


 Purchase Lean Welding Manufacturing Tools


Background in Lean Manufacturing  .