Case Study: Evaluation of Three PPE Solutions on Welding Productivity at a Large Defense Contractor

Results

Figure 1 shows a plot of the overall averages for each product solution by welder. For every welder in the study, the average productivity while wearing 9100FX was higher than the other styles tested. On average, the productivity while wearing 9100FX was 44% higher than while wearing the non-PAPR equipment (individual welders ranged from 13%-80% higher productivity).

Although the results from this seven-week study are not statistically significant, they do suggest welding productivity was improved when welders wore the 9100FX. Additionally, for welders in the study who had a week using a non-PAPR system and passive welding lens (Control Solution), productivity was higher when using a PAPR system with an ADF. A follow-up study with all welders using every system, equal replication of systems, and randomization of systems could be done in the future to verify the results statistically.

Feedback from the company suggested that productivity gains, particularly for the 3M 9100 FX, were strongly tied to two key features:

• The superintendent of welding shared that he felt the 3M solution, which features the XXi Auto Darkening Filter, “was much clearer and had better color clarity and contrast compared to the competitor ADF and the current passive lens in the Control Solution.” This was reported to have shortened the time between set-up to welding considerably, and it appeared to improve the weld quality, reducing the amount of rework needed.
• Additionally, the participants reported that they found the PAPR systems were more comfortable than the reusable half-face respirator, which allowed the welders to stay under the weld hood longer, taking less break time. The integrated nature of the 3M 9100FX system and competitor system (i.e., integrated weld lens, grind shield and respirator) was reported to have helped save time on donning equipment, repeated adjusting and fitting. The weld superintendent also shared, “Although both 3M and the competitor are similar in features, the welders indicated additional ease of use and comfort in the 9100FX compared to the competitor tested.” He believed this caused the difference in performance and worker productivity seen in the study.

Benefits related to worker health and safety from use of integrated PAPR systems for welding were also noted anecdotally during the study, namely reduced breathing resistance, fogging and the potential for eye injuries. The PAPR systems provided a higher assigned protection factor (APF) for the welders, compared to the control solution, while providing a consistent airflow across their face which workers reportedly found not only refreshing, but also significantly reduced fogging of safety glasses. The 3M XXi ADF in particular was also reported to have improved situational awareness for the workers, while the ergonomics and lighter wearing helmet suspension was reported to help reduce welder fatigue when using the 9100FX, compared to the competitor’s solution. Lastly, the integrated grind shield was believed to reduce the potential for eye injuries by not having to transition between a standalone welding helmet to a standalone grind shield, limiting the exposure to flying debris and foreign objects.

Discussion

This study was key to building the business case for adopting the 3M 9100FX solution across this shipbuilder’s production welding areas. The investment for such an undertaking is significant, in addition to the training and change management that must take place. Being able to document productivity gains over time within their own facility created the buy-in, and payback ROI needed from management, as well as the employees, to move forward.

Lastly, the welders indicated that the investment in the 3M 9100FX solution increased their morale and demonstrated the company’s commitment to their health and safety. Although such comments were anecdotal from the small group of employees included in this study, for this organization improving the safety culture was another key benefit from using the 3M 9100 FX product. This factor, along with the fact that the 3M welding solution demonstrated that it could help ensure the long-term financial stewardship of company resources, made a compelling case for conversion to the 3M welding solution provided.

*3M provided some of the 3M product for the study.
**The shipbuilding company in this study requested that the competitive product not be identified out of respect for the solution that was not selected.
3M provided analysis of the data.

Previously Featured on 3M Personal Safety Division's website.