Innovative product weldment has become a very important segment of our welding operation. Majority of our clients demand from us highly customized solutions that increase, weldment’s strength, resistance to impact, resistance to abrasion and improved functionality. These solutions demand from us not only improved welding procedures, and advanced welding skills, but also more advanced welding machines.
In the repair of engineered and innovative product weldment and fabrication of new one we cooperate with engineering firms specializing in the field utilizing the weldment. However, in repair of smaller innovative product weldments and fabrication of new small weldments clients usually opt to rely on our expertise.
Welding constrains of technologically advanced innovative products demand extensive planning and sometimes testing since the results are unpredictable. In case of new weldment the planning begins with interviewing client and finding out required functionalities. However, in weldment repair process we examine the damages and then plan their repairs. Even though we devote a significant effort to planning process, our projects always contain some challenges in their implementation. Nevertheless, these challenges are significantly reduced through planning process. We call this planning process feasibility study.
Please note, only about 20% of all projects in this category need feasibility study. Minor concerns in majority of projects are clarified in traditional way.
In our feasibility study we draw conclusions to basic question. Here are these basic questions:
The client pays for time devoted to our feasibility report and for our expertise. Small but complex projects include the feasibility study in the project price and we do not formulate the official report. However, in case of large projects we tend to include feasibility study as a separate position in our estimate and then in our invoice.
Our cost reduction initiatives depend on the type of innovative product, but even then the innovative product welding is rather costly. In general terms, we differentiate innovative products that are engineered and those without engineering input. Nevertheless, even with our cost reduction approach welding of innovative weldment is costly since the welding procedure is rather complex requiting skill, technology, knowledge and experience.
First, we treat innovative weldment as a prototype. The different patterns of cracks on the crane and their depth tell the story of equipment abuse, neglect and pushing to the limit. Then you continue with interaction between these cracks, then suddenly you realize that you haven’t seen a similar case yet. And then if you add structural bents to the puzzle and now you know it is a unique case. It is a prototype.
Second, we train our welder in the shop, prior welding the most crucial welds and client must pay for it. Innovative product weldment always have some complex welds. If these welds crack or material cracks close to them then it doesn’t make any sense to weld everything back how it was before, isn’t it? We must improve it and make it stronger. These stronger welds are often challenging due to significant modification of the procedure, and that is why we train the welder in shop to be familiar with this modification(s). If there is no place for mistake on your innovative weldment, than welder must be trained.
Third, any attempts to make a stronger weldment through, joint modification, different weld preparation, or unique consumable alloy increases the price. In this way client pays for our knowledge to make its innovative product weldment stronger.
Almost on any project we face challenges due to congested space, restricted visibility, necessary movement of welder’s hand similar to welding pipe instead of structural steel, necessary movement of welder’s hand similar to small tube welding, and weld preparation different from traditional beveling. In such situations even trained welder for the particular project, could make mistakes. These mistakes most often relate to different angular electrode positioning and related undercut, under-weld, and sometimes cracks.
In house magnetic particle testing allows us to identify in initial stage precise location of material cracks and weld cracks. It also allows us to test our own welds for cracks after weldment cooling process. Although, all our welds must go through independent Magnetic Particle Testing, but our in-house magnetic particle testing reduces the costs of retesting the failed welds.
The large multilayer welds play especially important role in innovative product weldments. Therefore, testing of these large welds is very important. The best way to test these large welds would be to X-ray them. Unfortunately, such testing method in case of large equipment or machinery would be impossible and impractical. Therefore we use Magnetic Particle Testing on each layer of multilayer welds. Sometimes, for cost reduction we test every second layer of multilayer welds.
We include in this category weld repair of damaged, cranes, excavators, loaders, grading machines, industrial presses, stomping machines, and stone crushers, ect. This category includes mainly damages to large and very expensive machinery or equipment. Clients with engineered innovative products expect cost control in the repair implementation process and very rarely accept addons. From other side, engineering firms clearly specify in their reports specific criteria that must be followed. These two factors traditionally leave us with highly restricted opportunity to reduce cost. However, there are still ways to reduce the cost of such welding repairs.
Even in most technologically advanced projects we are able to simplify welding procedures and suggest some cost saving approach to engineering firm. These suggestions could include changing joint assembly, weld preparation, material alloy, consumable alloy or preheat regime. Surely, we add some cost to the total price through a significant devotion of our time into feasibility report but client gains in reduction of labour hours, passed weld tests and lack of rewelds and stronger weldment overall.
The feasibility report in initial stage makes the work of Professional Engineer a little easier since they can communicate with us directly and we are on site taking measurements and images. With such technical support the engineering report becomes straight forward and Professional Engineer is assured that procedures will be followed.
The project must become win-win-win solution for all parties involved to take place. We put a maximum effort explaining to client what must be done, how we will do it and where are possible savings. Clients often opt very positively to cost reduction if they can contribute by utilizing their own resources. Additionally, we ensure through a clear communication that client understands exactly what we are going to do and how it will impact client’s operation.
From that perspective JW Portable Welding & Repairs acts as an intermediary between our client and an engineering firm. We respond to clients searching for a welding company connected to engineering firms specializing in particular fields. We also respond to engineering firms having challenging projects and looking for a welding company. Both, client and engineering firm can request our Project Report after project is paid for by the client. Our project report could be very useful to clients and engineering firms to develop valuable insights into similar projects of the same nature. Please contact us and there you can upload your images as well as your files including Professional Engineer report.
JW Portable Welding & Repairs provides a project report issued at the end of the project that includes all preparation tasks, preheat temperatures, post welding procedures, and images of all welds. Images of all welds could include images of layer by layer large welds as well as progress bits for modified welds.
We recommend project report for more complex large project with significant capital involvement. Such record can be very useful for potential weldment improvement in the future.
The request for project report must be specified in the P.O.
Majority of weldments in this category relate to changes of innovative product functionality. When our client decides to increase product’s capabilities and broadens its functionality, our role is to implement it. These innovative product weldments are usually manufactured from aluminum alloys, stainless alloys, or more sophisticated steel alloys. Their designs are complex and client asks us to make a better prototype.
Very often welder must be trained in welding aluminum on prototype due to lack of aluminum signaling for melting temperature. After welding, we then test the welded pieces for penetration and strength. Once satisfied we apply the procedure to the prototype while monitoring accumulation of heat. Surely, it is not a welding under constant temperature but it is very close to it.
Prior proceeding with prototype fabrication, we usually ask variety of questions attempting to find out details about the alloy as well as prototype’s impact on the manufacturing or operation. We often chose to take samples of material for laboratory testing in order to precisely determine the alloy, associated welding procedure for the alloy, and/or determine welding consumable suited best for this alloy. Additionally, we often have to see how the old weldment operates in order to improve this product.
Sometimes however, client relies on our expertise in urgent welding repairs of very complex weldments. We treat very seriously such situations and we tend to over-weld the weldments.
Occasionally we discover some flaws in engineering design and we tend to inform the client about them. Certainly, we try to fix them as much as possible in urgent situations but obviously our fixes has some limits. Some unique to industry weldments need to go through a redesigning process from time to time. Here is the example.
In fabrication of small innovative product weldments and in welding repair of weldments without participation of engineering company, we do not revile trade secrets. These trade secrets may include:
We make every effort to make clients aware of this policy in the initial interaction with them. However, sometimes we share some advice to clients on a budget dealing with complex damages and difficult situations. Here is one of such situations.
Aside of weldments our own products often do contain other non-metal materials such as acrylic (plexiglass), UV lights, wooden planks and artwork. However, our weldments involve traditional steel material in flats, HSS, rods and sheet metal in different thickness. Here is the link to our supplier and to another supplier. From that perspective we not only fabricate the weldment but also assemble the other components. And then deliver the finished product to our client.
It is important to realize that innovation of our products in essence refers to innovation of weldments, and especially to their forms and their functionalities. As skillful fabricators with mechanical backgrounds, certified millwrights, and mechanical engineers, we tend to fabricate movable weldments. Or, at least weldments with some movable parts. Also, since we do variety of metal art projects, and we tend to decorate weldments that have some recreational purpose.
Majority of our innovative products contain other materials aside of steel and this impact our delivery time. Projects that require more different suppliers take longer to deliver. Here is the list of our own innovative products containing our own designs:
The functionalities of our innovative products is rooted in the needs of our customers that require some degree of customization. Another key point is that our innovative products change the way our clients operate their businesses, way our customers perform tasks or workers perform their tasks. Our products impact also how clients approach opportunities and mitigate risks.
Most of our custom products are based on old, practical and useful technologies. These technologies go through our innovative ideas process to make innovative products. Therefore, all our innovative products contain technologies that work. But, our innovation changes the application of these technologies. Moreover, all our fabricated products go through some customization process prior delivery to our customers. The customization process allows us to make the short production series for clients that fit exactly their unique needs.
The customization process for our products involves fabrication, electrical, art and mechanical work. Additionally, we install our products or components manufactured by others. We also frequently distribute innovative products manufactured by others. With this in mind, we distribute only these products from other manufacturers that offer some kind of customization.
Moreover, we source our suppliers in following order: Canadian suppliers, American Suppliers and Asian suppliers. Furthermore, we have also tendency to change and modify the standardized supplied products to fit our requirements.