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Watched our tube rolling go from 20 minutes a joint to 6 after we fixed one dumb thing
Two years back our crew in Gary was rolling 2 inch tubes on a boiler rebuild and every joint took about 20 minutes of fighting. We blamed the operator and swapped guys twice with no change. Turned out the roller mandrel was out of spec by 40 thousandths and nobody had checked it in 8 months. New mandrel, same operator, 6 minutes a joint. Anyone else skipping the gauge check on their rollers because the joints still look okay?
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ivanross29d ago
Forty thousandths is a lot but here is the part that bugs me. You said the joints still look okay, and that is exactly how the bad ones sneak through. A roller that is out of spec does not always show up in the weld bead, it shows up in the grind time and the fit up on the next pass. We had a set that passed visual for weeks, then the X ray guy started failing them left and right. So the gauge check is not about looks, it is about keeping the same mandrel doing the same thing every shift. Check it at the start of every job and log it.
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