The Xiris Blog

How to Reduce Customer Returns from your Tube Mill

Posted by Cameron Serles on Tuesday, February 14, 2017 @ 04:00 AM

When a customer refuses to accept a shipment because of a quality problem, the cost escalates as soon as the tube leaves the plant. The cost of customer returns includes all product that gets returned from, rejected by or credited to a customer. It also includes the expense of sorting, investigations, meetings, reporting, shipping, handling and containment.  The tube producer may have to rework the product until it meets customer expectations, scrap it or, worse, send a team to the customer’s site to inspect each piece manually.  By adding weld inspection into a tube production line, the rate of defect detection will be higher as the weld inspection system will be able to detect, at a high level of accuracy, defects that are not easily detected by NDT equipment or manual operators.  With higher defect detection rates, better quality product will be shipped, ultimately reducing customer returns.

Feb 13 Blog Image 1.jpg(photo courtesy of www.demacmedia.com)

 

Reduce your customer returns! Justify an automatic weld inspection system using a ROI worksheet where you can enter your own mill data. 

 

    Download your FREE ROI Calculator Now!

 

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com or sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, Tube and Pipe welding, ROI, return on investment, productivity tools

How to Find Defects Sooner and Reduce Scrap on a Tube Mill

Posted by Cameron Serles on Wednesday, December 21, 2016 @ 05:00 AM

In a tube mill, production scrap can come from just about anywhere: tooling wear, bad material inputs, out-of-maintenance equipment or a process that is out of control.  Regardless of where it comes from, the creation of scrap costs tube fabricators a lot of money and time.  Since raw material accounts for the majority of the cost to make a tube, reducing the scrap rate by even a fraction of 1% can provide substantial savings to the tube fabricator.

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Typical Scrap Generated from a Tube Mill

(photo courtesy of www.roll-kraft.com)

Traditionally, defects are found on a tube mill at the end of the production line by existing NDT equipment or alert operators.  By placing an automatic weld inspection system right after the weld box, defects or weld zone variations can be detected earlier in the production process and can be removed from production prior to further value being added to defective products.  By detecting the defects automatically right after the weld box and not manually by an operator or inspector at the end of the line after cutting or bundling, a complete length of tube can be saved by responding faster to the out-of-control process.

The result is material savings of scrap tube because the process can be brought in control sooner, avoiding producing extra lengths of defective tube. 

Want to reduce scrap in your mill?  Justify an automatic weld inspection system using a ROI worksheet where you can enter your own mill data. 

 

    Download your FREE ROI Calculator Now!

 

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com or sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, Tube and Pipe welding, ROI, return on investment, productivity tools

Reducing Tube Mill Downtime with Weld Inspection

Posted by Cameron Serles on Wednesday, November 23, 2016 @ 03:00 AM

Tube mills require a large capital investment that often gets amortized over several years.  Even assuming that a mill is written down over an extended period, such as 10 years, the total cost of running a mill can be substantial when including the hourly amortized cost of the mill, the operating costs and related personnel costs.  Not surprisingly, minimizing mill downtime is always a priority for tube producers.  When a tube mill stops for planned events (such as product change overs, mill qualification, planned maintenance), or unplanned events (such as equipment failures, material input problems, shortage of operators, unscheduled maintenance), production stops.  For most tube fabricators, downtime is the single largest source of lost production time.  While there could be many reasons for a mill’s downtime, focusing attention on the constraints of the mill to ensure optimal use of resources is the most direct route to improved productivity.  When manufacturing processes get out of control on a tube mill, common trial and error solutions typically prolong the time needed to correct the process.  The result is high wastage and repair costs. 

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(photo courtesy of www.prweb.com)

In contrast, by implementing automated tools such as an automatic weld inspection system, mill downtime can be reduced by improving the use of resources needed to keep the process in control.  With this equipment, tube fabricators can get a better and more advanced warning of process issues that are moving out of tolerance so that the mill does not have to be shut down to fix major tooling or welding issues.

Want to reduce downtime in your mill?  Justify an automatic weld inspection system using a ROI worksheet where you can enter your own mill data. 

 

    Download your FREE ROI Calculator Now!

 

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com or sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, Tube and Pipe welding, ROI, return on investment, productivity tools

How to Reduce Quality Lab Time Associated with a Tube Mill

Posted by Cameron Serles on Wednesday, October 26, 2016 @ 10:04 AM

Lab time is a precious commodity.  As part of the changeover process on a tube mill, the tube to be produced must first be qualified to a desired level of quality in the lab. This line qualification process often includes cutting as many as three separate cross sections of a tube and sending them to the lab for processing where they get polished and photographed as micrographs. Once created, the micrographs can be measured or analyzed to verify that the weld structure of the tube meets the specifications required by the customer.  By using a weld inspection system that can accurately measure weld bead geometry and tube profiles, it may be possible to reduce the number of micrographs taken for each line qualification from a sample made for 100% of every change over to a lower, statistically relevant percentage.  The net result is that fewer line qualifications are required, leading to fewer tests (e.g., micrograph samples) performed in the lab, saving both lab time and lab personnel costs.

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Image of a Sample Micrograph

courtesy www.twi-global.com

 

Want to reduce your lab times?  Investigate how to justify an automatic weld inspection system using a ROI worksheet where you can enter your own mill data. 

 

   Download your FREE ROI Calculator Now!

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com or sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, Tube and Pipe welding, ROI, return on investment, productivity tools

How to Reduce Set-Up Time on a Tube Mill

Posted by Cameron Serles on Tuesday, September 27, 2016 @ 02:30 AM

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Every time a tube mill is changed over to run a new product, a set-up process must be performed to adjust the mill accordingly.  This process can be quite time consuming as a number of variables, input materials and equipment need to be adjusted to allow the mill to run the best quality product possible.  Reducing  the set-up process time and complexity is welcome news to all mill operators.  One approach is to add an automatic weld inspection system right after the weld box on the tube mill.  By adding such a system, immediate feedback of the weld geometry of the tube being produced can be provided to the mill operators as set-up adjustments are being made.  The result is a faster set-up process, less mill downtime and a more efficient tube mill.

 

Now, there's a powerful way to justify your productivity investment.  Use your own mill parameters to make an informed decision about buying a post weld inspection system.

 

  Download your FREE ROI Calculator Now!

 

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com 

Topics: quality control, Xiris, welding, Tube and Pipe welding, ROI, return on investment, productivity tools

Free ROI Calculator for Tube Weld Inspection Systems

Posted by Karen Serles on Tuesday, August 30, 2016 @ 02:30 AM

Two of the most important competitive advantages in tube production are the quality of the weld and the quality of the formed profile of the tube.  How can you improve your quality while also driving down costs and delivery times?

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The Xiris WI2000 Weld Inspection System helps Tube fabricators improve quality and save costs by reducing:

  • Mill Set Up Time
  • Lab Time
  • Mill Downtime
  • Scrap
  • Customer Returns

 

Now, there's a powerful way to justify your productivity investment.  Use your own cold, hard figures to calculate Return on Investment (ROI). 

 

 Download your FREE ROI Calculator Now!

Make an informed decision about a XIRIS WI2000 Weld Inspection System purchase and see how you can achieve consistently higher quality while reducing costs and increasing customer satisfaction.

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com 

Sign up to receive our Weld Video of the Month

Topics: quality control, Xiris, welding, Tube and Pipe welding, ROI, return on investment, productivity tools