Case Study Anti Spatter AMPCOLOY® Mylar
Case Study Anti Spatter AMPCOLOY® Mylar
Weld Spatters: The biggest enemy in any welding environment. It creates problem like messy welding area,
damages the body resting units & adds the fixture downtime. The maintenance teams have to go for additional
coating on the units or spatter protection sprays.
Problems arising due to weld spatters
Excessive cleaning
is required
Higher maintenance
& replacement cost
Increased
downtime
Trials:
Trials were conducted for Bajaj Auto Ltd. at Badve Mega Engineering in comparison with AMPCOLOY Mylar Block
against existing Mild Steel blackodised resting / clamping block.
First, we identified the pain area of the operator where heavy spatter deposition occurs on the welding fixture and
huge time & rigorous cleaning activities are required.
AMPCO METAL (INDIA) PVT. LTD.
Findings:
AMPCOLOY Mylar
After 720 jobs & 958 m welding
AMPCOLOY940 Mylar
After 4320 jobs & 5745 m welding
Mylar made in AMPCOLOY Mylar
Observations:
Cleaning is done after every 3-4 jobs, cleaning time approx 2 Mins.
One over all cleaning after end of the shift, 10-15 mins rigorous cleaning by chiseling, hammering etc.
Conclusions:
100 %
Reduction in
cleaning activities
70 Minutes
Time saved
per shift
20%
Productivity
increase per shift
(23 additional jobs
per shift)