Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH April 15 Analyses of the cost efficiency while using GSI SLV 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 training-cycle

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 TrainerWelding booth Aquisition costs16650,-€ (incl. additional PC) 9950,-€ (incl. fume extraction, welding table, external Equipment) „Fixed expenses“per week depreciation61,67€23.03€ interest (6%)9,25€5,53€ maintainance ( repair & service) 9,26€18,52€ rental fee3,11€5,19€

Schweißtechnische Lehr- und Versuchsanstalt Halle GmbH 9 Machine Hour Rate (2) Calculation of machine hour rate GSI SLV Welding TrainerWelding booth Aquisition costs16650,-€ (incl. additional PC) 9950,-€ (incl. fume extraction, welding table, external Equipment) „Variable costs“ per week power0,86€2,58€ consumption of shielding gas 15,18€25,56€ consumption of cutting gas (C 2 H 2, O 2 ) /5,95€ repair/service23,159,26€ water for cooling/0,08€ base material (plates)1,84€53,30€ operating materials2,20€6,65€ machine hour rate4,22€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. boothWelding 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. UV-Radiation Light-Radiation Fire hazard Welding fumes Noise emission Welding boothGSI 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. Weld pool Arc consumables Heat evolution  all parameters Welding boothGSI SLV Schweißtrainer 25%0% 25%10% 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!