Original Date: 07/21/2003
Revision Date: 01/18/2007

With the implementation of its Twin Head Welding Process, Electric Boat Corporation, Quonset Point Facility transformed a manual operation that resulted in operator fatigue and low productivity to a mechanized process that significantly increased productivity.

Traditionally, adapter rings were welded to spherical air flask bodies using the gas metal arc welding process where welders manually held the welding torch in place for long periods of time. The torch was held in one position while the heated flask, with the adapter ring tacked in place, was rotated on a turntable past the torch. The fatigue and heat associated with this process were detrimental to productivity, which is measured by the pounds of weld wire deposited per shift. The average weld deposition was 15 to 20 pounds per shift.

To eliminate fatigue and increase productivity, the employees and welding technicians at Electric Boat Corporation, Quonset Point Facility (EBQP) developed a two-headed mechanized spray welding machine using four motorized cross slides and joy sticks. The new two-headed welding machine now allows the welder to perform two welds simultaneously. Two separate rings are welded to the flask at the same time while the operator sits behind a darkened shield and operates the joy stick. The change to a mechanized process reduced span time by 50%, eliminated welder fatigue, improved weld quality, and increased the deposition rate to 60 to 70 pounds per shift.

For more information see the Point of Contact for this survey.