Good practices and investments related to Cleaner Production
Example No. 2
Modernisation of welding stations
Company:
FAMED Żywiec sp. z o.o.
Industry branch: electrical machinery industry (manufacture of medical equipment)
Resources in question:
- Materials
- Electrical energy
- Emissions into the atmosphere (dust and gaseous emissions)
- Waste
- Noise
Cost (implementation of good practice): High
(approx. PLN 1.4 million)
The company's manufacturing processes require the use of welding processes. They were carried out on stands equipped with 3 welding machines, welding in a carbon dioxide shielding gas mixture, using a welding wire. The stands did not have filtering and ventilation equipment, only individual exhaust fume cupboards removing the pollution to the atmosphere (mainly dust, about 0.504 Mg/year). Manually welded elements often required additional treatment - grinding, generating high wear on the grinding wheels. The additional treatment resulted in waste (worn discs) and energy consumption. When the welds were not suitable for processing or were defective, the elements were scrapped.
Applied solution:
The modernization of welding stands consisted in replacing the existing 3 stands with two welding robots: a one-stand one and a two-stand one.
The robots are equipped with two-stage filtration devices. The first stage (pre-filter) was recommended for health and safety reasons, in order to stop heavier dirt and extinguish sparks. The second stage (central filter with high cleaning efficiency of 99.8%) was recommended for the reduction of dust contamination. The use of robots allowed one to reduce disc wear and waste thanks to the precise execution of welds which no longer require additional treatment.
Obtained benefits and effects of the implementation:
The robots are equipped with two-stage filtration devices. The first stage (pre-filter) was recommended for health and safety reasons, in order to stop heavier dirt and extinguish sparks. The second stage (central filter with high cleaning efficiency of 99.8%) was recommended for the reduction of dust contamination. The use of robots allowed one to reduce disc wear and waste thanks to the precise execution of welds which no longer require additional treatment.
Obtained benefits and effects of the implementation:
- Easy operation and programming
- Improvement of the efficiency and rhythm of production
- High and reproducible welding quality (no need for frequent rework and less waste)
- Improvement of working conditions and elimination of tedious, monotonous and physically demanding work, elimination of cleaning operations and manual grinding of welds
- Reduction of material consumption (grinding discs)
- Waste reduction
- Reduction of dust (from 0.504 to 0.001 Mg/year) and gaseous pollutants
- Reduction of electricity consumption
- Noise reduction
Welding stands before modernisation
photo by: FAMED Żywiec sp. z o.o.
Welding process after modernisation
photo by: FAMED Żywiec sp. z o.o.
This
material has been subsidized by the National Fund for Environmental
Protection and Water Management. The Polish Cleaner Production Movement
Association is solely responsible for its content
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