"Even though we’re using the same amount of space, we’re now able to increase production and get a better output from the factory with fewer people."
Instead of one member of staff in a welding column & boom there are now two men in an operator room who monitor welding with four welding heads. This welding method is unique in the world.
“Even though we’re using the same amount of space, we’re now able to increase production and achieve better output from the factory with fewer people,” explains Jens Risvig Pedersen.
The towers grew in size and today the factory has 14 submerged arc welding circ seams on one tower section. A wind turbine tower consists of several sections. “The bottleneck spoiled the flow and other functions were kept on hold for too long,” says the CEO.
First a gantry welder (multi-seam welding station) was constructed with two heads, and when that worked, one more welding head was added. The factory now has four welding heads that can carry out welding work on the same tower section at the same time. Each step of the development took many months.
“Welding doesn’t constitute a bottleneck anymore. Now half of the welding machines may be idle when we manufacture sections of thin steel plates,” says Jens Risvig Pedersen.
“There’s always pressure somewhere in the production – that is, if your order book is full. But the pressure moves. Right now there’s pressure in surface treatment in that we now produce 18 offshore sections a week.”
Welcon A/S is a Danish company that primarily produces turnkey steel constructions.
They focus on the most productive welding methods. The newest welding methods are tested and documented before taken into use. The machinery makes Welcon able to produce a wide range of steel constructions, where the main emphasis is on towers to wind turbines.
Welcon has over 60,000 m2 of factory floorspace in operation.
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