Streamlining Welding Processes at Rhino:
An Employee’s Innovative Jig
At Rhino, we’re always looking for new ways to deliver the high-quality products we’ve become known for more efficiently. Recently, Alex Grabham, a Welder Fabricator who has been part of the Rhino team for seven years, developed a welding jig in his spare time that enhances the efficiency and production accuracy of our NPSA personnel doors. Alex’s innovative solution not only speeds up the process but also improves the quality and consistency of the final product.
The Problem: Aligning Steel Components for Welding
One of the challenges we frequently faced involved the precise alignment of two steel pieces that form part of the seal in our NPSA personnel doors. This alignment is a critical step because any misalignment could compromise the integrity and effectiveness of the door. Traditionally, the alignment process required measuring and clamping the pieces manually, which was time-consuming and introduced scope for error.
Moreover, longer steel components often required two workers – one to align and the other to clamp – making the process resource-intensive. While this method worked, there was always room for improvement, particularly regarding efficiency and reducing human error.
The Solution: A Custom-Built Jig
Inspired by Rhino’s company-wide culture of continuous improvement, Alex sought to design a tool that could streamline this part of our production process. His idea was simple: to create a jig to hold the steel pieces in place for welding without needing constant measurement and adjustment.
After drafting the design on a software package, Alex 3D-printed the prototype parts at home. Alex specifically tailored the jig for our welding needs – it allows the steel components to be easily aligned and securely held in place, ensuring perfect positioning before welding.
Testing and Refining the Design
Once Alex had the prototype ready, he conducted several tests to check its dimensional accuracy and overall functionality. As with any new design, a few tweaks were required, but the initial tests were promising. The jig performed as expected, simplifying the alignment process significantly.
Alex presented the prototype to his line manager, who immediately saw the jig’s potential to improve efficiency and precision. After some minor adjustments based on feedback, Alex printed and distributed the final version to every welder on our team.
Alex’s Impact
Alex’s jig has had a massive impact. It has increased the speed at which we can work, reduced the resources required, and improved consistency, accuracy, and quality. By eliminating manual measuring, the risk of human error has been reduced, ensuring more consistent results.
Alex’s dedication to finding a solution that enhances efficiency, reduces errors and improves the overall quality of our products is commendable, and we are very proud of his work. By taking the initiative and using his skills to design a custom jig, Alex has contributed to a significant process improvement that benefits his team and the entire company. His work exemplifies the ingenuity and proactive spirit that makes Rhino a leader in precision manufacturing.
