Data-driven Analytics in Welding and Cutting: Driving Productivity, Quality and Operational Efficiency

By Martin Meyer 

The integration of data-driven analytics into welding and cutting operations is transforming the industry by providing insightful, actionable intelligence that improves productivity and quality, ensures compliance, reduces gas and scrap, and enhances safety.  

Welding companies can leverage analytics to achieve measurable operational gains through productivity optimization, documentation management, and gas flow control. 

The welding and cutting industries have traditionally relied on experience, skill, and adherence to standards as the foundation for operational success. However, in an increasingly competitive and complex environment, these alone are insufficient. Data-driven analytics provides a structured approach to identifying inefficiencies, streamlining compliance, and improving decision-making. Although the prospect of collecting and analyzing data may appear daunting — often perceived as complicated or unnecessary, it has become essential for organizations seeking long-term competitiveness. 

From Data Collection to Actionable Intelligence

Collecting raw data on welding operations is only the beginning. True value arises when the data is analyzed and translated into clear, actionable guidance. For example, a golf simulator measures: launch angle, side angle, angle of descent, distance, impact, velocity, spin, height, roll distance, flight time, shot dispersion and curve. 

Knowing this data is helpful. But having software that analyzes the data and then explains exactly what and how much to change a golf swing is infinitely more useful.  

In the welding and cutting world, data software can gather and measure variables such as: parameters for each weld session, deposition rate, gas and wire consumption, consumable life prediction, weld quality, equipment maintenance schedules, welder certifications, WPS documents and more. Knowing this information is genuinely helpful. But interpreting these measures and providing managers and operators with concrete steps to improve an operation is infinitely more useful. 

Productivity, documentation and gas flow analytics are a few of the main areas that can have the largest impact on most fabrication and manufacturing shops.  

Productivity Analytics 

Productivity measurements and analysis allows companies to uncover bottlenecks, justify automation and optimize workflows. Two key metrics are arc time factor (“arc-on” time) and net deposition rate. By comparing this data between different sites or departments, different shifts, across different machines and projects, common issues start to emerge. Issues such as: poor part fit-up, parts not available, increases in scrap, cuts that are inferior, bends that are incomplete, fixtures that are inadequate, and excess wire and gas consumption occurring. Identifying these bottlenecks and addressing the root causes of them will quickly turn losses into gains. 

Take for example a heavy manufacturing customer. The CEO wanted a 20% increase in productivity. This sounded like a good goal and is not an uncommon request. The problem was that there was no baseline. The operations manager was asking, “20% increase from what?” By using analytic software and comparing a manual weld station to an automated station, a clear picture of production, quality, and deposition, was developed to justify an additional automation purchase. 

Additionally, and maybe more importantly, the data analysis also determined that 15 CWIs spent all day monitoring weld machines to ensure 100% WPS compliance for X-ray quality welds. By using software for this task, it freed up 15 CWIs to work on real issues and prep for new projects.  

Another manufacturer reduced robot programming time from 8–to-12 hours to 20 minutes, by using a software program designed for off-line robot programming (e.g., at a computer workstation off the shop floor). Not only did this free-up an operator for other projects, but it also increased the robot’s arc-on time to make more welds and ultimately more money. 

Another fabricator discovered that jagged cuts were increasing his scrap because the subsequent weld couldn’t meet the WPS. This increase in materials, combined with tariffs, inflated costs by 60%. Data analysis revealed that one ragged cut was costing this fabricator thousands. By investing in a million-dollar high-precision laser cutting system, the company actually saved money long term. 

One more example is a bumper fabrication company that was convinced their 50 welding operators weren’t performing well. Leadership noticed the welders were often not in their booths and were behind in production goals. After completing a full productivity study, the productivity data analytics identified material handling shortages as the root cause of low productivity. Essentially, the welding operators did not have parts to weld and spent their time locating and hauling parts to their booths. By adding forklift operators and material handlers, the fabricator increased its arc-on time from 10% to 13%. Or simply put, 20 parts per booth increased to 21. This change equated to producing an additional 50 bumpers per day, or $3.7 million in annual revenue. 

Documentation Analytics

Accurate documentation of weld qualifications, procedures, and certifications is critical for compliance and risk management. Specifically, gaining control over PQRs, WPSs and WPQs with welding management saves time. Efficiently reviewing all these specifications with one search feature makes life much easier. Never missing an expiration date or wasting time and money on welder qualifications is useful and perhaps essential. And finally, code checking and full support for ASME, AWS and ISO codes at your fingertips will most certainly save you from many headaches.  

A notable case involved a coke drum manufacturer that faced a major loss when one operator’s certification had expired. Without proper tracking, the company could not determine which welds he performed. Ultimately, the company had to reject the entire project — this cost huge money, time and credibility with its customer. Tracking data on each weld bead, each operator, on each shift would have made this mistake an easy grind and re-weld. 

Documentation analytics ensure full traceability and prevent such costly setbacks. Additionally, many companies achieve a two-to-five day reduction in administrative work per project due to better documentation management. And cost savings are realized when the system can prove it unnecessary to requalify PQRs and ensure that no welder certifications expire. 

Gas Flow Analytics

Shielding gas, often considered a static cost, is subject to inefficiencies including leaks, pressure and overconsumption (operators tend to turn up the gas when the weld isn’t correct). Analytic tools can track gas process parameters throughout an entire system from manifold to operator booth or automation cell. It can then detect anomalies and vitally important — notify managers when gas flow goes outside the set limits. 

In one shipyard with 400 welding stations, analysis revealed a 25% loss in gas leakage and overconsumption. In addition to several leaks, the average flow rates were significantly higher (57.21CFH rather than the prescribed 48.72 CFH). Through corrective measures, the yard achieved annual gas savings of 8,847.5 cu. ft. per welding station, which extended to more than $1 million saved in annual gas spending.

What Data Analytics is NOT

Data analysis should not be used to shame employees, diminish morale or use to brow-beat a department. Instead, proper use of data-driven analytics enables collaboration, reduces frustration, and fosters a culture of transparency and improvement. Operators benefit from clear guidance, supervisors gain reliable insights, and organizations improve overall quality and efficiency.

What Data Analytics IS

The adoption of data-driven analytics in welding is no longer optional, it is a necessity for organizations seeking to remain competitive. By transforming raw data into actionable intelligence, companies can significantly enhance productivity, ensure compliance, reduce waste and strengthen safety. Embracing analytics positions welding operations for sustainable growth and success.