Welding is integral to the automotive manufacturing process. Malben Engineering, an award-winning supplier of high-level welded assemblies to both OEMs and tier 1 automotive sector suppliers, has invested in a massive technical step change over the past three years.
Operational director, Luca Smargiasso says the introduction of a new vehicle model by a key customer necessitated the introduction of new, completely automated welding technologies. These include adaptive pulse welding, DC projection welders and controlled voltage spot welders as well as advanced variable pulse MIG welding technology.
Data-driven welding production processes
Malben Engineering’s welding production processes, backed by extensive quality controls, deliver an impressive 750 000 projection welds and 1,7 million spot welds monthly. The company is furthermore compliant with the automotive sector’s CQI 15 quality standard. It was one of the first tier 1 suppliers to achieve A-rating and green status – maintaining a zero margin for defects and a rejection rate of zero parts per million, significantly exceeding customer expectations.
Although Malben has welded both coated and uncoated mild steel automotive parts for decades, Smargiasso says that the automotive industry is using thinner gauge and higher tensile steels, which makes welding more challenging. There is a drive to go thinner with stronger materials, to reduce weight and improve fuel efficiency.
The advantage of Malben’s automation and attention to detail is predictability and consistency, which go hand in hand: “In our sector we are doing production welding for mass production runs. So, our welds must be exactly the same, every time,” explains Quinten Ballot, head of maintenance, who has extensive welding experience.
Over the past eight months, Malben has had zero rejections. Smargiasso explains: “It is like climbing a mountain. Everybody can do day one, most people can do day two, however, from day three they cannot continue and are in danger of falling. It is being able to do the same thing day in and day out over an extended period without letting your guard slip- which really counts.”
Data will set you free
Robust design of experiment processes and live data that is analysed in real-time set Malben Engineering apart. Plant manager, Jithin Kottikkal explains that the quality of the data provided enables the Malben welding team – which collectively has some 70 years of welding experience – to rapidly take the necessary action to ensure that quality controls remain within limits.
Quality control manager, Cheslyn Reid, adds: “We analyse the data, ensuring that it leads us in the right direction. We do not go into anything blindly, but instead carefully analyse what our process tells us – tracking it over a certain period and then implementing production line changes to ensure sure we are always ahead.” Ballot points out that strict process controls and team-based decision-making are also priorities. Smargiasso observes: “An adage that is often quoted is ‘the data will set you free’. Our success is also due to the discipline of our team, which takes pride in our brand and in working for Malben”
Real value from real-time adaptive welding
The real-time control of weld parameters is achieved by using pulse welding. “The welding parameters are adjusted in real-time during the weld process. If the gap between the welded parts varies due to dimensional tolerance allowances, the weld voltage and arc length are adapted accordingly.
Technical director Marco Smargiasso says that an important part of the Malben step change was a move from AC to DC projection welders, noting that that where robotic spot welders are still controlled by AC, this is carefully checked. “We monitor and measure the voltage. If there is something wrong, the processis immediately stopped. Monitoring current ensures we do not get a cold weld.”
Ballot observes that the quality welding that Malben achieves also relies on highly skilled team members.
“Malben not only employs experienced welders but actively builds skills within the company to keep pace with technology, and most importantly, with the requirements of our valued customers,” he concludes.
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