Welding Automation in the Aerospace Industry
Welding Automation in Aerospace Industry
Globally many aerospace industries have adapted to using automation for welding processes. In this article, the experts at nexAir share their KnowHow on the importance of welding automation in the aerospace industry and how it would help this industry Forge Forward.
Aerospace industries deal with the production of aircraft and spacecraft technology. These companies widely accept welding automation because the upgraded use of technology in production, welding, and handling of various resources helps increase efficiency and productivity all through the manufacturing process.
What is Welding Automation?
Welding Automation implements the use of robots for better performance and efficiency of the manufacturing of welds. This automation increases the speed, accuracy, quality and readily reduces the chances of errors that may occur in the welding processes.
Welding automation is now used by a wide range of automation industries for welding applications and vast production compared to manual welding. nexAir provides gases such as Argon that are used in automated welding machines. With our KnowHow, aerospace industries can adopt welding automation to make life easy and more enjoyable for welders by increasing the welding accuracy, quality, and precision and improving the welders’ skills.
Why should Aerospace Industries Implement Welding Automation?
Aerospace industries require welding automation for improved flexibility, safety and efficiency. Welding Automation will not only help your welding processes but make your business Forge Forward.
Flexibility
Relative parts of motors and airplanes are made of components that are often too large for humans to weld. Most times, numerous welders are needed to weld a part. Other parts may be made of exotic metals. High accuracy and precision are needed for efficiency, which explains why welding automation should be implemented. Working technology involving robots helps to minimize cost, save time, and convey high welding quality.
Safety
Welding robots are vastly becoming famous because they’ve proven to help reduce numerous risks that are associated with welders, such as radiation, burns, shock from electrics, and injuries, thereby increasing the production process.
Efficiency
Welding robots are better at precision, working with competence repeatedly without reducing their efficiency, unlike humans who are prone to fatigue after working for a while. Robots are wired to work without getting tired while constantly producing accurate results. This improves the physical integrity of the new product, fastens the entire manufacturing process, and increases the safety of the employees.
A very good manual welder can achieve a great outcome. A well-experienced welder makes accurate precisions in some areas, such as travel speed, voltage, and oscillation, but welding is a variable problem that must be resolved in time. Automation helps welders be outstanding and concentrate better on various tasks requiring solutions in split seconds, rather than repeatedly performing tasks that form a massive part of their time.
The introduction of welding automation by these industries has led to the drastic reduction in health issues relating to fatigue and stress and minimized the chances of injuries and accidents to the welders.
Welders are at liberty to make valuable contributions to the manufacturing process, thereby increasing productivity and profitability if they are not restricted to performing repetitive, time-consuming, strenuous tasks.
The Future of Welding Automation.
Over the years, welding automation has grown globally and is still growing. Many industries are now adding it into their processes; robots now revolutionize the industry, creating new standards for productivity, high-quality products, and the safety of the employees. Soon enough, it would become a staple in the Aerospace World. To make your company Forge Forward, you would need not only the quality gases (for welding and other processes) from us but also our KnowHow. Your company deserves the best; it deserves nexAir.
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Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.
The Hidden Costs of Gas-Related Downtime
When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:
- Production rescheduling that disrupts carefully optimized sequences
- Rush shipping fees to meet customer deadlines despite delays
- Quality inconsistencies when processes restart after interruptions
- Overtime costs to catch up after unplanned stoppages
- Reputation damage when delivery commitments are missed
For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.
From Reactive to Proactive: The Supply Continuum
Most facilities follow a predictable pattern in their gas management evolution:
Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.
Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.
Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory.
Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.
Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.
Customizing Solutions for Maximum Uptime
Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:
- For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
- For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
- For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
- For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.
This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.
Beyond Traditional Supply: Integrated Services for Total Reliability
Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:
Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions
These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.
Measuring Success: The Results That Matter
The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:
Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability
These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.
Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.
Looking out for your future
Get your career going on the right track with nexAir
Find out how nexAir KnowHow has impacted businesses all over the Southeast
Our expertise makes us more than a valuable partner, it makes us headlines