Realizations

Modernization of welding line

Project Specification

Area	800 m²
Completion time	Six weeks
Team	12 specialists (welders, electricians)
Welding methods	MIG, TIG
Tests	NDT (radiography, ultrasound)

About the project

Project characteristics

The client is engaged in industrial machinery manufacturing and needed to upgrade its entire welding line. The old line was inefficient, generated downtime and did not meet quality requirements. Global Group was tasked with a comprehensive process redesign. From dismantling to commissioning the new system with NDT inspection.

Scope of work

Implementation stages

Dismantling the old production line

Safe withdrawal of obsolete equipment, disposal in accordance with standards, preparation of the hall for new installations.

Assembly and welding of new support structures

Prefabrication of elements in the workshop, transportation, assembly of steel structures. Welding by MIG and TIG methods, quality control at each stage.

Installation of NDT system for quality control

Installation of equipment for non-destructive testing (radiography, ultrasound). Calibration of equipment, trial tests.

Electrical work: power supply, commissioning of machines

Installing switchgear, running cables, connecting machines. Electrical testing, commissioning, commissioning of the control system.

Training of the team of operators

Imparting knowledge of new line operation, safety procedures, diagnosis of basic problems.

Challenges and solutions

Design challenges and their solutions

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Tight schedule

The client could not afford long production downtime. We had to act efficiently and precisely.

Coordination of several teams

Welders, assembly specialists, electricians. Everyone worked simultaneously. Communication and division of tasks were key.

Integration with existing systems

The new line had to work with older machines. This required additional testing and adaptation.

Project Manager on site

A dedicated coordinator kept an eye on the schedule, responded to problems, and communicated with the client daily.

Prefabrication in the workshop

We prepared the components before assembly on site. As a result, it went quickly on site. No downtime related to welding.

Parallel tests

Electrical and welding teams worked simultaneously in different zones. We did not wait for the completion of one stage to start the next.

Effect

End results

Project completed three days ahead of schedule

Thanks to good coordination and effective planning, we met (and even beat) the deadline.

The line passed NDT tests without any objections

All welds, connections and electrical installations received positive test results.

Operators ready to work

After the training, the client team worked independently. They knew how to operate the system and respond to basic problems.

Customer returned with another order

This is the best feedback for us. A few months later, the client commissioned us to expand another line.

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