Nozzle Cost Reduction Charts
Perhaps no manufacturing process has as many
variables as does a welding operation. In
order to develop these Nozzle Cost Reduction charts, it was
necessary to make a set of assumptions appropriate for
various welding variables. The following charts are based on
those assumptions and data obtained from testing PerfectArcs™ nozzles
in a variety of laboratory and real-world conditions. No two
weld operations are exactly alike and the assumptions we have made
may not be representative of your specific welding operations.
(Assumptions are listed in Note below Chart 4)
The functional lifetimes of PerfectArcs self-cleaning
nozzles are dependent upon many factors--including the
welding environment, operator skill level, possible physical abuse
and/or misuse of the nozzle, and other variables that we
can neither predict nor control. For that reason we are including Cost
Reduction values for four different scenarios. The scenarios
are:
Chart 1. PerfectArcs nozzles increase nozzle lifetime by a factor of 15
Chart 2. PerfectArcs nozzles increase nozzle lifetime by a factor of 10
Chart 3. PerfectArcs nozzles increase nozzle lifetime by a factor of 6
Chart 4. PerfectArcs nozzles increase nozzle lifetime by a factor of 3
These examples are based on a hypothetical company that is small (uses only 520 nozzles per year); larger companies with more extensive weld operations may see proportionally higher savings.
Chart 1. 15X If PerfectArcs nozzles last 15 times longer than ordinary nozzles
| Number of nozzles needed for one year |
Annual costs for nozzles (PerfectArcs costs include nozzle costs and PerfectArcs processing) |
Annual costs related to labor to clean and change nozzles |
Annual costs due to lost productivity while cleaning/ changing nozzles |
Annual miscellaneous costs related to nozzles |
Increase in profits (%) |
Annual savings ($) |
|
|
Ordinary Nozzles |
520 | $3,120 | $126,720 | $42,308 | $1,900 | None | None |
|
PerfectArcs Nozzles |
35 | $1,260 | $1,262 | $416 | $180 | 34.2% | $170,930 |
Chart 2. 10X If PerfectArcs nozzles last 10 times longer than ordinary nozzles
| Number of nozzles needed for one year |
Annual costs for nozzles (PerfectArcs costs include nozzle costs and PerfectArcs processing) |
Annual costs related to labor to clean and change nozzles |
Annual costs due to lost productivity while cleaning/ changing nozzles |
Annual miscellaneous costs related to nozzles |
Increase in profits (%) |
Annual savings ($) |
|
|
Ordinary Nozzles |
520 | $3,120 | $120,672 | $42,308 | $1,900 | None | None |
|
PerfectArcs Nozzles |
52 | $1,872 | $1,270 | $416 | $267 | 34.0% | $170,223 |
Chart 3. 6X If PerfectArcs nozzles last 6 times longer than ordinary nozzles
| Number of nozzles needed for one year |
Annual costs for nozzles (PerfectArcs costs include nozzle costs and PerfectArcs processing) |
Annual costs related to labor to clean and change nozzles |
Annual costs due to lost productivity while cleaning/ changing nozzles |
Annual miscellaneous costs related to nozzles |
Increase in profits (%) |
Annual savings ($) |
|
|
Ordinary Nozzles |
520 | $3,120 | $120,672 | $42,308 | $1,900 | --- | None |
|
PerfectArcs Nozzles |
87 | $3,132 | $1,283 | $416 | $447 | 33.8% | $168,770 |
Chart 4. 3X If PerfectArcs nozzles last 3 times longer than ordinary nozzles
| Number of nozzles needed for one year |
Annual costs for nozzles (PerfectArcs costs include nozzle costs and PerfectArcs processing) |
Annual costs related to labor to clean and change nozzles |
Annual costs due to lost productivity while cleaning/ changing nozzles |
Annual miscellaneous costs related to nozzles |
Increase in profits (%) |
Annual savings ($) |
|
|
Ordinary Nozzles |
520 | $3,120 | $120,672 | $42,308 | $1,900 | --- | None |
|
PerfectArcs Nozzles |
174 | $6,264 | $1,318 | $416 | $894 | 33.0% | $165,156 |
Note: The above charts are based on manual welding operations for a hypothetical factory that employs 10 full-time welders and has annual sales of $10 million with a net profit of 5% (before interest and taxes). [Results for companies with robotic weld operations may be similar to these manual weld examples--but could vary greatly due to differences in robot "down times" while nozzles are being cleaned and/or replaced.] Assumptions for charts on this page: Welders work one 8-hour shift per day for 52 five-day weeks. Welders have a constant "backlog" of work--and time spent not welding decreases production output. Ordinary nozzle lasts for 40 hours. Cost of ordinary nozzle=$6.00. Welder labor rate + burden = $72.00 per hour. Time to clean ordinary nozzle (average over its lifetime) = one minute per hour. Time to clean PerfectArcs nozzle (average over its lifetime) = three seconds per hour. Miscellaneous costs include damage to welding guns from banging gun to clean, inefficiencies due to frequent "start-stops", weld reworks due to "end of life" welds, damage to nozzles while being installed, order processing costs, and storage costs.