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(1)

The Real Cost of Laser Welding

Presented at Great Designs in Steel

Stan Ream, Laser Technology Leader

Jim Tighe, CFO

(2)

Outline

• How do you measure cost?

• How does your boss measure cost?

• The “ABCs” of laser welding costs.

• Blank welding study cases

• How important is the laser in the laser system?

• Other factors that influence welding cost.

(3)

How to you measure cost?

- or how are you graded? -

• Cost of the laser

• Cost of the motion system

• Cost of associated automation

• Operating consumables

(4)

• How do Controllers look at cost?

– Sunk Cost

• “Can’t we continue using what we have?”

– Cash Outlay

• “What’s this going to cost?”

– ROI / Break-Even

• “When are we going to be ahead?”

• We need to speak a common language to come to

the right answer

– The “ABCs” (activity based costing)

(5)

Process

Elements

Operational

Cost Summary

Cost

Elements

Accountant

Speak

Production

Speak

(6)

Process Elements

Operational

Cost Summary

Cost

Elements

Direct Variable

Consumables

Capital

Equipment

Other Costs

Tooling

Payroll

Employees

Overhead

Sunk Costs

Acc

oun

tan

t Speak

P

rod

uct

ion

Sp

ea

k

Process Time, Load/Unload Time,

Maintenance Cycles, Useful Life

Allocated Floor Space

Custom Fixturing, Useful Life

Air, Gas, Electricity…

Staffing Quantity and Level, Shift

Routines

Cos

t /

P

roducti

vit

y

“Fully

Burdened

Cost per

Part”

“Cost of a

Part”

(7)

Much to Consider

- don’t even try to read this now -

Welding Process Cost Calculator:

User Input - Variable with Process User Input - Infrequent Calculated Output - Metrics Calculated Output - Cost Need to "fix" to become part of the model

Cost Elements

Input Units

Operation Elements

Operational Cost Summary

Output Units

Com pres s ed Air $ - $/100cf standby compressed air usage - cfh process compressed air usage - cfh

Helium Gas (laser) $ 34.36 $/100cf laser helium gas usage 1.70 cfh Consumable Cost (laser and process gas) 41.84 $/hr

helium plasma assist gas usage (60 cfh x 2) 120.00 cfh Nitrogen Gas (laser) $ 3.95 $/100cf laser nitrogen gas usage 0.35 cfh CO2 Gas (laser) $ 3.90 $/100cf laser CO2 usage 0.07 cfh Argon Shielding Gas $ 6.54 $/100cf welding trailing shield gas usage - cfh Other Gas $ - $/100cf

Wire $ - $/lb. filler wire diameter - inch filler wire speed - inch/min

Electric Power $ 0.0600 $/(kw-hr) Runtime electric power 120 kw Runtime Electric Power $ 6.34 Standby electric power 50 kw Standby Electric Power $ 0.36

Total Electric Cost $ 6.70 $/hr

PROCESS EQUIPMENT - 6kW CO2 Laser $ 400,000 $ process equipment space 5,000 ft.2 Avg. PROCESS EQUIP. - Depreciation 7.81 $/hr PROCESS EQUIPMENT - Salvage Value % 10 % load time 0 sec Avg. FIXTURING EQUIP. - Depreciation 0.00 $/hr Avg. PART HANDLING EQUIP. - Depreciation 68.35 $/hr FIXTURING EQUIP. - ___ $ - $ Travel speed 260 in/min 6.5 m/min Average Total Equipment Depreciation 76.16 $/hr FIXTURING EQUIP. - Salvage Value % 10 % Weld length 60.00 inch/weld 1.5 m Average Interest on Equipment 12.58 $/hr number of welds per part 1 welds/part Average Depreciation & Interest (8 years) 88.74 $/hr

PART HANDLING EQUIP. - 2 Station Clamp Line $ 3,500,000 $ indexing time per part - sec/part Asset Value at End of 8 Years $390,440

PART HANDLING EQUIP. - Salvage Value % 10 % unload time - sec

1st YR PROCESS EQUIP. - Depreciation 17.36 $/hr 1st YR FIXTURING EQUIP. - Depreciation 0.00 $/hr 1st YR PART HANDLING EQUIP. - Depreciation 151.91 $/hr Total Equipment Depreciation 169.27 $/hr First Year Equipment Interest 25.39 $/hr First Year Depreciation & Interest 194.66 $/hr Cycle Time 13.85 seconds/part Output Coupler $ 2,000 $/ea. Output Coupler life 1,000 hours

Cooling Water Filters $ 1,000 $/ea. Cooling Water Filters life 1,000 hours Blower $ 5,000 $/ea. Blower life 4.00 yr

Focus Optics, 2 sets $ 6,000 $/set Focusing Optics Life 1,000 hours/set Long Term Parts Costs 15.52 $/hr

Beam Delivery Optics $ 10,000 $/set Beam Delivery Optics Life 10,000 hours/set Beam Trap $ 1,000 $/ea. Beam Trap 500 hours Clamp feet $ 1,000 $/ea. Clamp feet 3,000 hours Belts $ 1,000 $/ea. Belts 1.50 yr Laser RF Tube $ 22,000 $/item RF tube life 1.60 yr Laser Vacuum Pump $ 2,500 $/item Vacuum Pump life 2.50 yr Operator Burdened Wage ( req'd) $ 20.75 $/hr Operator Loading 2 operators/line Handler Burdened Wage $ 17.70 $/hr Handler Loading 4 lines/handler Supervisor Burdened Wage $ 38.00 $/hr Supervisor Loading 6 lines/supervisor

Maintenance Burdened Wage $ 28.00 $/hr Maintenance Loading 6lines/maint tech Direct Labor Cost 56.93 $/hr

Tool Maker Burdened Wage (indirect) $ 34.00 $/hr Tool Maker Loading (indirect) 12 lines/tool maker

Engineering Support Staff burdened wage (indirect) $ 60.00 $/hr Engineering Staff Loading, including QA 6 lines/engr. Indirect Labor 12.83 $/hr

Maintenance Functions

Laser Tuning 2.00 hrs/month Focus Optics Cleaning 12.00 hrs/month Beam Path Alignment 6.00 hrs/month Other Maintenance 16.00 hrs/month Total scheduled maintenance 36.00 hrs/month Unscheduled maintenance 16.00 hrs/month

Total Maintenance 52.00 hrs/month Process Utilization 88% % of possible meals & breaks 0.73 hrs/shift

Plant Space Cost with Utilities $ 45.00 $/ft.2/yr facility schedule 3 shifts/day Plant Availability 720 shifts/yr yearly schedule 240 days/yr Plant Availability 5,760 hours/yr Cost of Money 5 %/yr Process Availability 5,232 hours/yr

Direct Facility Cost 39.06 $/hr

N ew E qu ip m en t O /H Lo ng -T er m P ar ts D ir ec t V ar ia bl e P ay ro ll

(8)

Blank Welding Cost Theme

- already a very well known laser welding application -

shock absorber

A-Pillar

B-Pillar

roof reinforcement

lift gate inner

wheel house

side ring

rear door inner

front door inner

floor pan

front rail

engine rail

wheel house

(9)

The Example Welding System

(10)

Base Case System Features

• 2 Machine Operators

• 2 Moving Clamps

• 6kW CO

2

Laser

• Mechanical Beam Switch

• Semi-Robotic Loading

• Full Robotic Unloading

(11)

Laser Blank Welding Process Notes

• Quality and Productivity Are Driven by:

– Edge Preparation

– Fit-up

– Process Alignment

Concavity

Mismatch

Ideal

(12)

Many Things Can Go Wrong

Mismatch

Mismatch

Concavity

Lack of

Penetration

Convexity

Lack of

Fusion

(13)

Steady Trend to Thinner Gauge

- greater process precision required -

0.8 mm to 1.9 mm

0.7 mm to 1.2 mm

1996

(14)

Cautionary Cost Comments!

• Consumable costs used in the following cases

are not absolute or necessarily current.

• Equipment costs are amalgams of past and

current information, not highly accurate.

• Welding speeds are conservatively stated.

• Calculated cost comparisons are believed to be

directionally accurate but not absolute.

(15)

Baseline System Cost

- for analysis only…not current or actual -

• 6kW CO2 laser:

$500,000

– Includes portion of plant-wide chiller system

– Includes beam delivery to both stations

• 2 Station Clamp Line: $3,500,000

– Includes robots

– Includes conveyors

(16)

Baseline System Consumables

• Electricity

– Laser

– Chiller

– Machine

• Gas

– Laser: helium, nitrogen, CO2

– Welding process: helium, argon, CO2

– Beam path: nitrogen or clean, dry air

(17)

Replacement Components

- short and long term…examples only -

• Laser

– Output coupler and/or output window (3-6 mo.)

– Cooling water filters (3-6 mo.)

– Blower (3-6 yr)

• Beam delivery

– Final focusing mirror (3-6 mo)

– Beam path mirrors (2-5 yr)

• Clamp line

– Beam trap (1-3 mo.)

– Clamp feet (9-12 mo.)

– Belts (1-2 yr.)

(18)

Baseline Optics Maintenance Time

- example for analysis only -

• Laser

– Resonator tuning (2 hr/mo)

– Output coupler/window cleaning (2 hr/mo.)

• Beam path

– Mirror cleaning (2 hr/mo.)

– Mirror alignment (2 hr/mo.)

(19)

The Cost of Floor Space

• Portion of building depreciation

• Lighting

• HVAC

• Maintenance

(20)

Cycle Time Elements*

- one of two stations @ 6 m/min weld speed-

1.

Pick & Place Part A

2.

Index Part A Into Fixture

3.

Clamp Part A

4.

Pick & Place Part B

5.

Stage Part B to Part A

6.

Clamp Part B

7.

Cycle Start

8.

Weld Head Move into Position

9.

Weld (part length / travel speed)

10.

Cycle Stop

11.

Unclamp Fixture

12.

Switch Beam to Station 2

13.

Lift Welded Part & Exit

14.

Retract Fixture

Single Station Cycle Time = 36 seconds

Beam-On Percentage = 42%

(21)

• Same parts & operating sequence

• 2 Operators

• No down-time included

Cycle Time Elements*

- both stations @ 6 m/min weld speed-

Dual Station Cycle Time = 19 seconds

Beam-On Percentage = 79%

(22)

Some of the Inputs to the Base Cast

Cost Elements

Input

Units

Operation Elements

Compressed Air

$

-

$/100cf

standby compressed air usage

-

cfh

process compressed air usage

-

cfh

Helium Gas (laser)

$

34.36

$/100cf

laser helium gas usage

0.80

cfh

helium plasma assist gas flow per station

60.00

cfh

Nitrogen Gas (laser)

$

3.95

$/100cf

laser nitrogen gas usage

0.20

cfh

CO2 Gas (laser)

$

3.90

$/100cf

laser CO2 usage

0.04

cfh

Argon Shielding Gas

$

6.54

$/100cf

welding trailing shield gas usage

-

cfh

Other Gas

$

-

$/100cf

Wire

$

-

$/lb.

filler wire diameter

-

inch

filler wire speed

-

inch/min

Electric Power

$

0.0600

$/(kw-hr)

Runtime electric power

120

kw

Standby electric power

50

kw

PROCESS EQUIPMENT - 6kW CO2 Laser

$

500,000

$

process equipment space

5,000

ft.2

PROCESS EQUIPMENT - Salvage Value %

10

%

Cycle Start gas flow

1

sec

FIXTURING EQUIP. - ___

$

-

$

Travel speed

240

in/min

6

FIXTURING EQUIP. - Salvage Value %

10

%

Weld length

60.00

inch/weld

1.5 m

number of welds per part

1

welds/part

PART HANDLING EQUIP. - 2 Station Clamp Line

$

3,500,000

$

Beam Switch time per part

2

sec/part

PART HANDLING EQUIP. - Salvage Value %

10

%

unload time

0.5

sec

Beam-on Time Per Part

15.0

sec

N

e

w

E

qu

ipm

e

nt

D

ir

e

c

t

V

a

ri

a

bl

e

(23)

More Inputs to the Base Case

Output Coupler

$

2,000

$/ea.

Output Coupler life

1,000

hours

Cooling Water Filters

$

1,000

$/ea.

Cooling Water Filters life

1,000

hours

Blower

$

5,000

$/ea.

Blower life

4.00

yr

Focus Optics, 2 sets

$

6,000

$/set

Focusing Optics Life

1,000

hours/set

Beam Delivery Optics

$

10,000

$/set

Beam Delivery Optics Life

10,000

hours/set

Beam Trap

$

1,000

$/ea.

Beam Trap

500

hours

Clamp feet

$

1,000

$/ea.

Clamp feet

3,000

hours

Belts

$

1,000

$/ea.

Belts

1.50

yr

Laser RF Tube

$

22,000

$/item

RF tube life

2.00

yr

Laser Vacuum Pump

$

2,500

$/item

Vacuum Pump life

2.50

yr

Operator Burdened Wage ( req'd)

$

20.75

$/hr

Operator Loading

2

operators/line

Handler Burdened Wage

$

17.70

$/hr

Handler Loading

4

lines/handler

Supervisor Burdened Wage

$

38.00

$/hr

Supervisor Loading

6

lines/supervisor

Maintenance Burdened Wage

$

28.00

$/hr

Maintenance Loading

6

lines/maint tech

Tool Maker Burdened Wage (indirect)

$

34.00

$/hr

Tool Maker Loading (indirect)

12

lines/tool maker

Engineering Support Staff burdened wage (indirect)

$

60.00

$/hr

Engineering Staff Loading, including QA

6

lines/engr.

Maintenance Functions

Laser Tuning

2.00

hrs/month

Focus Optics Cleaning

12.00

hrs/month

Beam Path Alignment

6.00

hrs/month

Other Maintenance

16.00

hrs/month

Total scheduled maintenance

36.00

hrs/month

Unscheduled maintenance

16.00

hrs/month

Total Maintenance

52.00

hrs/month

meals & breaks

0.73

hrs/shift

Plant Space Cost with Utilities

$

45.00

$/ft.2/yr

facility schedule

3

shifts/day

yearly schedule

240

days/yr

Cost of Money

5

%/yr

O

/H

Lo

ng

-Te

rm

P

a

rt

s

P

a

y

rol

l

(24)

Base Case Outputs

Operational Cost Summary

Output

Units

Consumable Cost (laser and process gas)

15.01

$/hr

Runtime Electric Power

$

6.34

Standby Electric Power

$

0.36

Total Electric Cost

$

6.70

$/hr

Avg. PROCESS EQUIP. - Depreciation

9.76

$/hr

Avg. FIXTURING EQUIP. - Depreciation

0.00

$/hr

Clamp Line & Material Handling

68.35

$/hr

Average Total Equipment Depreciation

78.12

$/hr

Average Interest on Equipment

12.90

$/hr

Average Depreciation & Interest (8 years)

91.01

$/hr

Asset Value at End of 8 Years

$400,452

1st YR PROCESS EQUIP. - Depreciation

21.70

$/hr

1st YR FIXTURING EQUIP. - Depreciation

0.00

$/hr

1st YR PART HANDLING EQUIP. - Depreciation

151.91

$/hr

Total Equipment Depreciation

173.61

$/hr

First Year Equipment Interest

26.04

$/hr

First Year Depreciation & Interest

199.65

$/hr

Cycle Time

18.50

seconds/part

Total Hourly Cost

$

236.54

$/hr

Net Productivity

171

parts/hour

(25)

Modify the Base Case Elements

• Add Seam Trackers ($100k)

• Increase Welding Speed to 9m/min

• Modify load sequence

• No Other Changes

blank travel

plasma light

assist gas nozzle

helium assist gas

focus mirror

flat mirror

welding laser

beam input

focusing beam

fiber optic to detectors

collimator

visible laser

tracking

camera

(26)

Modified Cycle Time Elements*

- one of two stations @ 9 m/min weld speed-

1.

Pick & Place Part A

2.

Index Part A Into Fixture

3.

Clamp Part A

4.

Pick & Place Part B

5.

Stage Part B to Part A

6.

Clamp Part B

7.

Cycle Start

8.

Weld Head Move into Position

9.

Weld (part length / travel speed)

10.

Cycle Stop

11.

Unclamp Fixture

12.

Switch Beam to Station 2

13.

Lift Welded Part & Exit

14.

Retract Fixture

Single Station Cycle Time = 25 seconds

Beam-On Percentage = 40%

(27)

• Same parts on each clamp

• Operators need improved timing

Modified Cycle Time Elements*

- both stations @ 9 m/min weld speed-

Dual Station Cycle Time = 12 seconds

Beam-On Percentage = 66%

(28)

Impact of Seam Tracking

• 37% Increase in productivity

• 27% Cost Reduction per part

• $1.01 vs $1.38 per part

Total Hourly Cost

$

237.54

$/hr

Net Productivity

235

parts/hour

(29)

Upgrade the Laser

• Replace the 6kW CO

2

Laser with 8 kW

fiber-delivered laser (disc or fiber laser)

• Eliminate helium gas shielding

• Eliminate beam switch time

• Keep seam tracking

• Increase welding speed to 12 m/min

• No net increase in system cost, i.e. assumes

alternate initial design with this laser

(30)

Fiber-Delivered Cycle Time Elements*

- one of two stations @ 12 m/min weld speed-

1.

Pick & Place Part A

2.

Index Part A Into Fixture

3.

Clamp Part A

4.

Pick & Place Part B

5.

Stage Part B to Part A

6.

Clamp Part B

7.

Cycle Start

8.

Weld Head Move into Position

9.

Weld (part length / travel speed)

10.

Cycle Stop

11.

Unclamp Fixture

12.

Switch Beam to Station 2

13.

Lift Welded Part & Exit

14.

Retract Fixture

Single Station Cycle Time = 23 seconds

Beam-On Percentage = 33%

(31)

• Clamp functions and manual loading

become greater portions of cycle time.

Fiber-delivered, 8kW Laser*

- both stations @ 12 m/min weld speed-

Dual Station Cycle Time = 10 seconds

Beam-On Percentage = 75%

(32)

Impact of Change to 8kW Fiber-Delivered Laser

• 54% Increase in Productivity

• 39% Reduction in Cost/Part

Total Hourly Cost

$

224.51

$/hr

Net Productivity

363

parts/hour

(33)

Summary Conclusions

• Fiber-delivered (1 um) lasers are a better choice for

laser blank welding.

• Strong return on welding system performance can

be achieved with improved process precision.

• Understanding the true cost and value of

(34)

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