Rivet welding workshopWorkshops with riveting and welding substitutes: the core production base for modern manufacturing

A first-class rivet shop is the cornerstone of the manufacturing industry, and the quality of industrial products above 60% depends directly on the professionalism of its production workshop.

Rivet welding workshop is an operation place specialised in joining and manufacturing of metal structures, integrating the complete production process of material preparation, welding processing and quality inspection. The riveting and welding substitution workshop, on the other hand, pays more attention to theFlexible production capacityrespond in singingCustomised requirementsWe are able to provide professional welding services to multiple customers at the same time.

The modern riveting workshop is no longer a “welding workshop” in the traditional sense, but a combination of automated equipment, digital management system and standardised processes.Advanced Manufacturing Unit.

01 Planning and Layout of a Modern Rivet Welding Shop

A scientific and reasonable workshop layout is the basis for guaranteeing productivity.Functional area divisionis a primary consideration in the design of a rivet shop.

A typical rivet shop should contain the following core areas:

• material storage area: For storage of raw materials such as steel plates, profiles, etc., with shelving systems and clear labelling management

• Unloading preparation area: Setting up equipment such as shears, plasma cutters, etc. for preliminary processing of materials

• welding area: Different workstations such as manual welding area and robot welding area according to product type.

• Semi-finished goods turnaround area: Temporary storage areas between processes to ensure smooth flow of logistics

• Finished product inspection area: Equipped with various testing equipment for quality verification

• Surface treatment area: Follow-up treatments such as sandblasting, spraying, etc.

Logistics path designDirectly affects workshop efficiency. Excellent workshop layout adopts U-shape or linear material flow pattern to reduce material handling distance and frequency. Welding station spacing is usually maintained at 3-5 metres, not only to ensure that the operating space, but also to facilitate the passage of material handling equipment.

Environmental control is also an important part of workshop design.ventilation systemWelding fume emission standards must be met, and each workstation is equipped with a local exhaust device;Lighting systemsIt is necessary to ensure that the illumination of the working surface is not less than 300 lux;Power ConfigurationTo meet the demand for simultaneous use of high-power welding equipment.

02 Rivet Welding Substitute WorkshopCore equipment configurations

The level of equipment directly determines the technical capability of the foundry.Diversification of welding equipmentIt is the basis for meeting the needs of different customers.

Modern riveting and welding foundry shops are usually equipped with the following combination of equipment:

• Robotic Welding Systems: For high volume, highly repeatable products to ensure consistency

• Gantry automatic welding machine: for long weld seams on large structural parts

• Portable welding equipment: meets the needs of on-site maintenance and special-position welding

• laser welding machine: Precision welding for high precision and small deformation requirements

Auxiliary equipmentEqually important. The workshop should be equipped with metal processing equipment such as large coiler (which can handle steel plates with a thickness of more than 30mm), hydraulic bending machine (with a pressure of more than 1,000 tonnes), and a series of cranes (with a lifting capacity of 5-50 tonnes), to form a complete processing capacity.

The level of testing equipment reflects the level of quality assurance in the workshop.Three-dimensional measuring instrumentUsed to check the dimensional accuracy of large structural parts;Ultrasonic Flaw Detectorrespond in singingMagnetic particle flaw detection equipmentFor weld quality inspection;Mechanical Performance TesterUsed for sampling and testing the strength of welded joints.

03 Production process and management system of the riveting and welding shop

Standardised processes are key to ensuring consistent product quality.Production Planning ManagementIt is the starting point of workshop operation. OEM workshop needs to establish multi-project parallel management mechanism, reasonable scheduling, to ensure that each customer order is delivered on time.

The complete riveting process includes:

1. Drawing Process Review: Analyse product manufacturability and determine optimal process solutions

2. Material Preparation: Preparation of base materials and welding consumables according to process requirements

3. Bevelling: Welding bevels by mechanical or plasma machining

4. pairwise positioning: Use of special tooling to ensure assembly accuracy

5. Welding implementation: Perform welding operations in accordance with welding procedures

6. weld treatment: Grinding and cleaning of welds, cosmetic repairs

7. quality control: Perform non-destructive testing and dimensional inspection

8. Surface protection: Sandblasted and coated on request.

Site management levelIt directly affects production efficiency and safety. The implementation of 6S management (sorting, straightening, cleaning, cleanliness, quality and safety) is the basic requirement of an excellent riveting and welding workshop. The equipment is placed in a fixed position, tools are managed in a fixed position, and the area is clearly labelled to create an orderly production environment.

04 Quality control system for riveted and welded foundry shops

Quality is the lifeblood of the foundry.Total Quality ControlThe system should cover every step of the process from raw materials to finished products.

Welding consumables management is the source of quality control. Workshop needs to establish welding consumables warehouse, control the temperature and humidity of the warehouse (temperature ≥5℃, relative humidity ≤60%). Welding rods and fluxes are dried and kept warm according to the requirements, and there are complete records of issuance and recovery to prevent moisture from affecting the welding quality.

Key points for welding process control include:

• Welder qualification management: Ensure that every operator is licensed and regularly reviewed

• Process discipline inspections: Monitor welding parameters for compliance with process regulations

• Process self-inspection and mutual inspection: Checks and confirms when the operator has completed each process.

• Non-destructive testing applications: Selection of appropriate test methods and ratios according to product requirements

Quality traceability system is the core advantage of the OEM workshop. Through the implementation of the product identification system, the material batch, process parameters, operators, inspection results and other information of each workpiece are recorded, so that the whole process can be traced. When quality problems occur, the cause can be quickly located and corrective measures taken.

05 Staffing and Skill Requirements for Specialised Rivet Welding Shops

Human resources are the workshop’s most important asset.Rationalisation of team structureIt is the basis for keeping the workshop running.

A typical rivet shop should be staffed with the following professionals:

• Welding Engineer: Responsible for process design, problem solving and technological innovation

• Production Supervisor: Responsible for production plan implementation and site management

• welder: Different levels of qualification: primary, secondary and tertiary.

• quality control personnel: Responsible for raw material, process and finished product inspections

• Equipment maintenance staff: Responsible for routine maintenance and troubleshooting of equipment

Skills training systemIt is the key to remain competitive. Excellent workshops have well-established training mechanisms, including:

• pre-service training: New employees must receive safety and skills training and pass the test

• On-the-job training: Regularly organise training in new technologies and techniques

• accreditationOrganisation of welders for international certification (e.g. ISO 9606)

• skills competition: Promoting Skill Exchange and Enhancement through Competitions

Foundry shops also need to develop their employees’Customer Service AwarenessTechnical staff need to be able to communicate effectively with customers to understand requirements and provide professional advice. Technical staff need to be able to communicate effectively with customers, understand needs and provide professional advice; production staff need to establish the concept of “the next process is the customer” to ensure that each product meets the requirements.

06 How to chooseQualified Rivet Welding Substitute Workshop

When choosing a partner, the overall capabilities of the foundry need to be assessed in a number of dimensions.on-site inspectionIt is the most intuitive way to assess.

It should be focused on when visiting the workshop:

• device status: Equipment is in good condition and maintenance records are complete

• On-site management: Material is arranged in an orderly manner, and aisles are clear.

• product quality: Sampling of in-process and finished products for appearance quality

• Employee Operation: Observe whether employees are operating in accordance with procedures and whether protection is in place

Qualificationis the basic threshold. Qualified foundry shops should have:

• ISO9001 Quality Management System Certification

• Industry-specific qualifications (e.g. pressure vessel manufacturing licence)

• Welding system certifications (e.g. EN 15085 Railway Welding Certification)

• Environmental and Occupational Health and Safety Management System Certification

Cooperation CasesIt is the best proof of ability. The workshop is required to provide successful cases of similar products, and it is better to visit the use of delivered products on the spot. At the same time, understand the workshop’s main customer groups and industry reputation, and choose partners with good reputation.

With the advent of Industry 4.0 era, intelligent riveting workshop is becoming a trend. By introducingInternet of Things (IoT) technologyThe welding parameters can be monitored in real time and the quality data can be analysed automatically.digital twinProduction processes can be optimised in a virtual environment before being put into production.

Choosing a professional riveting and welding foundry is essentially choosing aReliable external production sites. Excellent workshop can not only provide high quality welding products, but also become a strategic partner of the customer enterprise, to deal with the market challenges together, to achieve win-win development!