Overcome the Challenges in your Manufacturing Operations

24 Feb 2023

Manufacturers in the welding industry face many challenges such as rising cost pressures and changing expectations of new welders. In this article, we will share how the new Deltaweld® system is designed to overcome these challenges.

Rising Cost Pressures

Rising costs will eat into the manufacturer’s profitability and prevent the manufacturer from bidding for projects competitively. There are three ways in which the new Deltaweld® system can help manufacturers to combat rising costs.

1. Eliminate non-value-added activities in production.

When the new Deltaweld® is paired with an Intellx™ Pro or Intellx™ Elite wire feeder, manufacturers will have access to the Accu-Pulse® technology, a pulsed MIG process developed by Miller®. Unlike traditional MIG welding, Accu-Pulse® has a 28% wider operating window and a more forgiving arc. This means that even inexperienced welders who are unable to maintain consistent torch angles and stick-out are able to produce quality welds in production. In turn, welders can spend more time producing parts instead of performing rework. Accu-Pulse® also produces less spatter and lower heat inputs when compared to traditional MIG welding. Consequently, welders will spend less time grinding spatter and rectifying issues such as distortion and burn-through.

2. Increased flexibility and capability to take on a wider range of jobs.

With the ever-changing demands of different clients and projects, it will be very costly for manufacturers if they have to constantly invest in new technologies and assets. As such, the new Deltaweld® system is designed to give manufacturers the ultimate versatility. For example, when the Deltaweld® 500 welding machine is paired with the Intellx™ Elite wire feeder, manufacturers will have access to a wide range of welding programs for steel, stainless steel, aluminium, nickel etc. In addition, the Deltaweld® 500 is equipped with a dedicated constant current gouge mode specifically designed for gouging up to 9.5mm carbons. Traditionally, manufacturers will invest in different welding machines to weld different materials and to perform gouging. This usually results in higher upfront costs as well as maintenance costs. With the new Deltaweld® system, manufacturers will be able to do more with less.

The Accu-Pulse® process on the new Deltaweld® system will also give manufacturers the ability to weld in a variety of joint types and positions, with the simplicity of a one wire, one gas, and one welding process solution. Currently, most manufacturers use short circuit MIG welding for out-of-position welding. This process usually results in lack of fusion, lack of penetration and increased spatter. On the other hand, Accu-Pulse® is able to deliver a consistently broad and deep penetration profile with minimal spatter for out-of-position welding. 

3. Identify welding costs so improvements can be made.

As the saying goes, you can’t improve what you don’t measure. To allow manufacturers to have better visibility of their welding operations, the new Deltaweld® system is equipped with Insight Core™, a passive, real-time weld monitoring tool from Miller®. Besides measuring each welder’s productivity levels, Insight Core™ can also help manufacturers to identify the costs in their welding operations by tracking labour, shielding gas and wire consumption. Manufacturers can leverage this information to make improvements and reduce costs.

Changing Expectations of New Welders

As more and more experienced welders retire from the workforce, manufacturers have to focus on hiring and training new welders with less experience, in order to keep their operations running smoothly. Today’s welders expect a better work experience, and giving them old welding machines that are difficult to setup and operate will affect the manufacturer’s ability to attract and retain talent.

Bearing this in mind, Miller® designed the new Deltaweld® system to deliver a user experience that today’s welders expect.

1. The new Deltaweld® system takes only 14 minutes to assemble, as compared to the three hours it used to take for the old Deltaweld® system.
2. Welders no longer need to walk back to the welding machine to make any process or parameter changes, since all the controls are now located on the Intellx™ wire feeders.
3. The Intellx™ wire feeders also come with an intuitive display and no hidden menus, making it very easy to set up and operate. The Intellx™ Elite wire feeder comes with a large full-colour LCD screen that displays on-demand graphics and clear instructions to welders.
4. Because Accu-Pulse® has a 28% wider operating window and a more forgiving arc, as compared to traditional MIG welding, welder training time is reduced, and even inexperienced welders can quickly produce high-quality welds in production.

Make Your Move

The new Deltaweld® from Miller® is designed to help manufacturers reduce costs and meet the expectations of newer welders. Make Your Move to the new Deltaweld® system today by reaching out to us at SGOffice@MillerWelds.com