Jim's Cover Pass: Writing out tribal knowledge in a metal fabrication shop

Tribal knowledge is great in a metal fabrication shop, but what happens when the tribe retires? There are benefits of evaluating manufacturing processes and having written weld procedures to ensure consistent, quality work. Getty Images

Q: Recently I was promoted to shop manager of our small welding fabrication company. This company has always trained the employees for specific jobs by having them work with the senior welders to gain tribal knowledge. I would like to create some work instructions and use welding procedures, but I just don’t know where to begin.

A: While many companies have survived for years by passing on information this way, it is always good to have written procedures to maintain integrity.

First—and this will take the most time and effort—you will need to begin documenting current procedures. Be certain that all of your welding power sources are calibrated for amperage and voltage. For every project or product that is manufactured, request that the welder document the process, electrodes, gases, amperage, voltage, wire feed speed, heat treatment, and any other critical data. You will also need to document the material type, size, cut length, and order of operation. This may also include any required preparation such as sawing, shearing, bending, and machining before and after each part or project is complete. You might also want to document the reasonable amount of time required to produce the product.

Next, as you review all of the data collected and begin to create the work instruction sheet, it would be beneficial to include the senior welders in the discussion. Match this information with a technical drawing or print of each part. Decide the appropriate range of parameters that are acceptable. The completed work instruction and technical print need to be written in a way that even a novice employee can follow. Determine if your products should be following any of the welding codes by AWS, ASME, API, or any other regulatory organization. If so, then the appropriate codes will need to be acquired and followed.

Finally, use the collected data to create the welding procedure specification (WPS), and test the procedure to create the procedure qualification record (PQR). Each welder will be required to test and qualify for every welding procedure involved with the manufacture of a stated product. You may find that some of the employees are better-suited to various procedures and processes.

This type of undertaking usually takes a fair amount of time and persistence. It also requires the buy-in of both administration and employees. Documentation also involves periodic review and changes when required. By using proper work instructions, quality technical prints, and documented procedures, you can help your company develop a strategic approach to effective, efficient, and economically productive manufacturing.