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Schweißtechnische Lehr- und Versuchsanstalt Halle GmbHSchweißtechnische Lehr- und Versuchsanstalt Halle GmbH
26. Apr 2023
Analyses of the cost efficiency while using GSI Analyses of the cost efficiency while using GSI SLV Welding Trainer in training of weldersSLV Welding Trainer in training of welders
Presentation of results
Michael Bednarzik, Hochschule Anhalt (Köthen)H.-J. Kaftan, Hochschule Anhalt (Köthen)Dipl.-Ing. IWE Silvio Schulz, SLV Halle GmbH
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 2
Introduction of project
Goal of the project: Economical analyses of Virtual Welding Training Systems (GSI SLV Welding Trainer) in
comparison to the traditional training of welders.
Calculation of real data in terms of costs, enviromental conditions, health and safety and motivation.
Design: -Welding processes MAW und TIG-underlying training time: 1 week (5 days)-detailed recording of consumption of materials, consumables, gas, power etc.-consideration of costs for a welding instructor
Duration: April-Juli 2012
Project: Bachelor‘s Theses
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 3
Introduction
Virtual Welding Training Systems
versus
Welding booth
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 4
GSI SLV Welding Trainer - Overview
Arbeitsplatz Schweißtrainer
GSI SLV Welding Trainer & an additional Computer in order to use e-learning software.
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 5
Day-Sequence
-Boot up the computer / setup the training system-Introduction by the Welding Instructor (once)-Follow practices according the training program (curriculum)-Assess the computer scoring independently
-Duration of practices max. 1-1,5 hours
-Change to the separate E-Learning program -Learning theoretical basics by self-study
-Rotate between practices and e-learning all the day
Sequence of a training day at the GSI SLV Welding Trainer
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 6
Day-Sequence
-control welding machine (consumable, shielding gas etc.) -preparation (cutting base material, grinding)-introduction by welding instructor-demonstration -welding trial-follow up works (cooling test piece, fracture test)-evaluation of the test piece together with the welding instructor
-cleaning up the welding booth at the end of the day
-the average of real welding time a day is approximately 30%
Sequence of a training day in a welding booth
trai
ning
-cyc
le
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 7
Explanation of Machine Hour Rate
Machine hour rate: - is a parameter of management accounting
- includes all the costs while using a machine
- that parameter does not includes labor costs
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 8
Machine Hour Rate (1)
Calculation of machine hour rates
GSI SLV Welding Trainer Welding boothAquisition costs 16650,-€
(incl. additional PC)9950,-€ (incl. fume
extraction, welding table, external Equipment)
„Fixed expenses“ per week per week
depreciation 61,67€ 23.03€
interest (6%) 9,25€ 5,53€
maintainance ( repair & service)
9,26€ 18,52€
rental fee 3,11€ 5,19€
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 9
Machine Hour Rate (2)
Calculation of machine hour rateGSI SLV Welding Trainer Welding booth
Aquisition costs 16650,-€ (incl. additional PC)
9950,-€ (incl. fume extraction, welding table,
external Equipment)„Variable costs“ per week per week
power 0,86€ 2,58€consumption of shielding gas
15,18€ 25,56€
consumption of cutting gas (C2H2, O2)
/ 5,95€
repair/service 23,15 9,26€
water for cooling / 0,08€base material (plates) 1,84€ 53,30€
operating materials 2,20€ 6,65€
machine hour rate 4,22€ 5,19€
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 10
Explanation of cost comparison method
Cost comparison method: - is an economical parameter
- all costs that result in the training process
- that parameter also includes labor costs
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 11
Expenses
What do the different expenses include?
Fixed expenses: - depreciation- interest- maintainance- rental fees- labor costs of an Instructor (50% less for the Welding Trainer )
Variable expenses: - Material consumption - consumption of operation materials (shielding
and cutting gas, water)- consumables - Power- repair and service
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 12
Cost comparison method
Cost comparison of different economical situations in the workshop
Welding Trainer
Weld. booth Welding Trainer
Weld. booth
Aquisition costs
16650,-€ 9950,-€ 16650,-€ 9950,-€
Fixed expenses
9265,-€ 12057,-€ 9265,-€ 12057,-€
Variable costs
701,-€ 1674,-€ 1867,-€ 4465,-€
Fixed & variable c.
9966,-€ 13731,-€ 11132,-€ 16522,-€
Difference per year.
3765,-€ 5390,-€
Utilised capacity 30% Utilised capacity 80%
Amortisation will achieved after 1,8 and 1,2 years
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 13
Health and safety
Comparison in terms of health and safety.
Welding booth GSI SLV Schweißtrainer
100% 60%
100% 65%
100% 75%
100% 30%
100% 15%
Harmful impacts are lowered on about 50%!
ca.50%
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 14
Practical relevance
Comparison in terms of practical relevance.
Welding booth GSI SLV Schweißtrainer
25% 0%
25% 10%
25% 25%
25% 10%
100% 45%
There will be reached a practical relevance of very good 45%!(Not regarded the real torch, using of helmet, gas, power source…)
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 15
Students-Evaluation
What do the students say after the training session at GSI SLV Schweißtrainer?
- …combination of practical training and computer equipment is very interesting….
- …we had a lot of fun..- …adjustment of errors during the training session was great….- … the scoring create a competition in the group ….- … I was especially impressed by e-Learning software .…
- … after achieving good scores at a high level, the motivation goes down….
- ….anytime everybody wants to weld in a real enviroment….
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 16
Summary
Summary and outlook
1. The machine hour rate of GSI SLV Schweißtrainer is about 20% less than that of the welding booth.
2. An Amortisation regarding to the higher price will achieved after 1.2 or 1.8 years. That depends on the utilised capacity of the workshop.
3. The health risk can be reduced to 50%.4. The practical relevance of the GSI SLV Welding Trainer will be
assessed at 45%.5. Adjustment of errors immediately during welding is very special.6. As a result of the scoring system a competition is developing between
the students. That increases the motivation.7. The students can get theoretical knowledge in parallel to practical
training.8. After achieving a high scoring at the final level the motivation goes
down.9. The recommended training time should not be longer than 1 week.
Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 17
End
Thank you for your attention!