Welding, joining of two work pieces to form one, is a precise, reliable, costeffective and “high tech” method for joining materials. Its development and growth is essential for growth of the manufacturing sector.
Where metal needs adhering, a welder is needed. Welders help build metal products from power plants to space vehicles. In India, the Industrial Training Institute (ITI) program give the skills need for entry level jobs in the welder trade and job opportunities anywhere in the world. One of the most challenges is the declining enrolment in ITI’s. Entry qualification, age limit to join industry, and the unfortunate public image of welding as an endeavour in decline is actually pushing many talented and energetic people into other fields.
Welding, shortage of skilled welder, the core of it all hasn’t changed. It is not surprising that the percentage of workers who can weld and who work in the manufacturing industries is on the decline. We are not attracting enough young people into welding careers. There are many noble careers in the welding field. All of us in the welding industry know that welding is special.
We noticed the biggest problem in this area when we established an ITI. The results of the investigation have vindicated the need to revise the welder curriculum, welder environment must become more attractive, and the industry must “upgrade” the existing workforce through better basic training and the industry to grant welders greater recognition and status for their work.
KEYWORDS: Welding, Welders, ITI, Welding Industry, Skill Gap, Develop Current Employees.
1. WELDING IS EVERYWHERE
Welding is in nearly everything we use. If it involves metals, almost certainly there will be a weld somewhere [1]. Welding plays a significant role in the defence, rocket bodies, passenger aircraft, military jet fighter planes, automobile bodies, heavy machinery such as that used in mining, steel structures, oil and gas pipelines, power generation industry, etc., This is understandable, since welding is used not only for the manufacture of almost everything made of metal, but it is the maintenance tool which keeps our power plants, refineries and other vital functions, etc.,[2].
Welding is a chain made of unique links and any broken link breaks the whole chain [1]. The links are: skilled welding professional, metallurgy, chemistry, mechanical engineering, electrical engineering, physics and the technological aspects of welding. The world comes together because of welding.
2. WELDER
The most important part of the welding system is the welder. Welders are people who must have skill and ability tomanipulate equipment to produce welding [3]. The quality of the resulting weld is heavily dependent upon the skill of the individual welder (Figure 1). Weld in a variety of positions and using their knowledge of welding and metals and may also examine welds to insure they meet standards or specifications [4]. Welders can accomplish incredible feats, from welding at the depths of ocean to incredible heights and welding in extreme cold or extreme hot.
Figure 1: Welding at SWI.
3. INDUSTRIAL TRAINING INSTITUTE
Workers who do the actual welding have usually learn the skills on the job, only occasionally through Industrial Training Institute (ITI) and Apprenticeships
3.1 Training System
The Directorate General of Training (DGT) under Ministry of Skill Development and Entrepreneurship, Government of India offers a range of vocational training courses catering to the need of different sectors of labour market. The vocational training programmes are running under the aegis of National Council for Vocational Training (NCVT). Craftsmen Training Scheme (CTS) and Apprenticeship Training Scheme (ATS) are two pioneer programs under NCVT for propagating vocational training. Welder trade under CTS is one of the most popular courses running on pan India through Government and Private ITIs.
After passing out of the training programme, the trainee is awarded National Trade Certificate (NTC) by NCVT which is recognised worldwide [5].
3.2 Welder Trade – Course Structure (Table 1)
Duration of the course : One yearEntry Qualification : 8th standard & age 14 years minimum
Table 1. Course Structure [5]
4. KARTHIKEYAN PRIVATE ITI
Most trade schools teach “how” to weld, but rarely teach “about” welding and metals. There is a big difference. It is one thing to learn “how” to do something and another “what” to do with what you have learned [6].
Worked in various fabrication industries in India and Abroad and participated in many training programme, seminars, symposium and technical talk related to welding. Professionally qualified and certified by AWS, TWI, ASNT. In a country that accords the highest importance to degrees, Indian Labour Report and the manufacturers across the country are reporting dire shortage of welders and welding professionals.
Keeping all these in mind and based on my previous experience, we decided to “serve the place of birth” after carefully considering the proposal, we have established Sumeka Welding Institute (2007). National Council for Vocational Training (NCVT) and Directorate General of Employment and Training (DGET), New Delhi granted affiliation to our Institute Karthikeyan Private ITI to conduct one year ITI course in Welder Trade from February 2012.
4.1 Educational Tours to Facilitate Learning
To bridge the gap between the industry and institute needs what we are essentially trying to do is bridge the gap between institutes and industry by way of practical industry visits, project implementation programs and such. It works both ways - the students gain practical exposure while industries can recruit students for jobs, projects, training, etc., [7].
Took my welder trainees on a field trip to Trichy and Bengaluru (Figure 2, 3). We wanted the trainees to see the latest trends in welding and help the students to be aware of their latent potential and cultivate creativity to become experts in welding technology. We bring our industry wisdom into the classroom with the combined focus on technical training and practical job site skills that will help trainees find a job. Without skilful welders, welding wouldn’t be able to win ground.
Figure 2: SWI Trainees Field trip to Exhibition at Trichy 2008.
5. APPRENTICESHIP TRAINING
ITI candidates can join Apprenticeship programme in different types of industries leading to National Apprenticeship Certificates (NAC). Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor in ITIs.
The training enhances the skill as required by the industry and generate industry ready skill workforces. By the way of training the industry productivity increases and the nation can meet the global requirements. Boost your skills and enhance your employability. The value of apprenticeship is that the students can learn in real workplace conditions. But the programs can be costly to the manufacturer because the student is not at full productivity during the learning process. And skilled workers at the industry are not as productive if they have to spend time training the apprentices.
Only about few percent of employers train apprentices for all trades. This means that there is an opportunity for more percent of employers to actively participate in the initiative to train apprentices that are looking to enter the welding and metal fabrication trades [8]. Apprenticeships, of course, are key to developing welding skills.
6. CONFLICTS IN THE ITI EDUCATION SYSTEM
Vocational education is an important part of the education systems in India. ITI’s prepares people for a specific trade.
6.1 Lower Rate of Admissions in ITI
A chronic need for skilled welders for industries in our country and at the same time lower rate of admissions in ITI every year (Table 2). Enrolment rates in the concerning low because of social fears surrounding welding jobs. Education tends to push teenagers toward a three year polytechnic or four year college. Governments are giving importance to higher education.
Figure 3: KITI Trainees Field trip to NWS 2013 at Bengaluru.
6.1.1 Admission system
Entry qualification for ITI welder trade: passed in 8th standard is the minimum requirement. Now the 10th standard students did not able to study the subjects such as their local language, science, english and mathematics due to there is no failed students through exam till 8th standard (all passed). This is very very distressed matter. We are constructing big buildings without foundation (basic education).
Table 2. Welder Trade Statistics
(Source: ncvtmis.gov.in as on 29/11/2022)
Total no of ITI’s for Welder Trade: 2937 (Govt: 1811, Private: 1126)
The developing nation in India, most of the students are studying up to 10th standard, 12thstandard and they shown very much interest to go for higher studies in a polytechnic, college where the minimum qualification is just passed 10th standard or 12th standard in one or more attempts. So ITI’s are not getting the enough students, reluctant to start new trades and ITI’s.
Our Suggestion: The minimum qualification 8thstd for ITI welder trade shall be lifted to 10th std pass or fail. Give the opportunity to the failed one. Otherwise the supplementary candidates and the students, who had studied up to 10th standard, will lose that chance to become a technician in several field and it may lead to ‘scarcity’ of ITI candidates in future.The admission norms for polytechnic/college shall be changedto 60% and above marks is required to join any diploma or degree in a single attempt.
6.2 Employment
According to the Industrial Labour Act, the minimum age limit is 18 years to join in an industry. In the present situation, 8thstd + ITI qualified technicians would not be able to get an opportunity for his job on completion of the study. So they lose their hope and divert to go for some other jobs irrelevant to their trade. It will be a waste of time and money for these technicians who want to enter welding profession.
That says something about having a strong academic background before the pursuit of skill training [9]. There can be some physical requirements that trainees need to meet to attend ITI and industry. For example, trainees may be need to be capable of lifting objects and making necessary motions to complete certain tasks depending on the program in which he enrol.
6.3 Apprenticeship Training
The employers prescribing the minimum qualification 10th standard is required to apply/ engage for apprenticeship training for welder trade whereas the 8th standard is minimum qualification to join the welder trade in ITI.
1. Hindustan Aeronautics Limited, Bengaluru: Total marks scored in SSLC.
2. Indian Oil Corporation Limited: Matric with 1 year ITI welder
3. DMRL, DRDO, Hyderabad: 10th class
4. Vikram Sarabhai Space Centre, Thiruvananthapuram: Candidates should attach self-attested copies of certificates of their qualification acquired from SSLC/ SSC onwards.
5. Age limit: 16 to 21 years for trade apprentices.
Our Suggestion Eligible Apprentices: A person who possesses minimum educational qualification prescribed for a trade is eligible to undergo apprenticeship training.
6.4 ITI Welder Syllabus
We reviewed the syllabus. The competency based curriculum for the welder Trade is developed by Central Staff Training and Research Institute (CSTARI), Kolkata. National Instructional Media Institute (NIMI), Chennai is actively involved in the development, production and dissemination of instructional media packages comprising of books on trade theory, trade practical, test /assignment and instructors guide.
Trade Practical book is to be used for shop floor instruction/ learning and it contains 284 pages for 840 notional training hours per year. Whereas Trade Theory book covers the knowledge aspects concerning each practical exercise and it contains 227 pages for 240 notional training hours per year. Much of the theory beyond the basics has been of no value. In addition to the Welder Trade, the following new trades are introduced: Welder (GMAW and GTAW), Welder (Pipe) and Welder (Structural).
Our Suggestion: Convert one year duration to two years so that ITI welder trainee attained 18 years old to enter the company job and integrating the entire welder trades to one.
6.5 Extension of Admission
Actual academic session: August to July. Directorate General of Training is extending of admission closing date every year and the revised training schedule from October or November to July. Insufficient schedule to learn one year course in 9 or 10 months.
7. WELDING INDUSTRY
We are a well-established, mature industry with the solid track record in technology and process advancements. The reputation of welded components for being reliable and economical, the industry’s commitment to research and development and the dedication of its workforce - as signs of welding industry’s strength [4]. Welding provides a way for the students to build a lifelong career.
8. CHALLENGES IN WELDING SKILL
Welding technology advanced and strengthened its position to be the leading method for metal joining in India and globally. However, there have been a lot of challenges to overcome in moving forward.
a. The welding and joining industry is vital to each one of us, but it is rapidly approaching a critical stage in its ability to supply the skilled welders needed for manufacturers to produce the products necessary for growth. To succeed in welding, we need good materials, the right equipment and proven procedures. Most of all we need skilled personnel.
b. One of the major challenges facing the welding industry is the unfavourable image of the welding profession in the mind of the general public. Some say the welding is a static industry - that there is nothing to learn about joining metal with metal. Welding is still perceived by many as a crude and dirty process.
c. Welding is an extremely complex field. Today’s technological advancements require that one evolve from “the art of welding” to the “science of welding.” Our industry depends upon education that prepares the next generation to meet the challenges ahead. There is always something new to learn. Thousands of new welders needed to bolster shrinking workforce.
d. Challenges of vertical welding
e. “How can I convince new people to enter the field of welding when the pay scale is so low?” Unaware of the earnings potential and possibilities for growth in our industry.
f. Our interactions with the students reveal that in teaching, more emphasis is placed on theory than on practical, field exposure and competency development.
9. WELDER SKILL GAP
The welding skill gap issue is a global concern and it is only getting worse as each year passes. It’s hard to find people that want to work as a welder and that want to grow with a company. We are all having a challenge of finding qualified welders and we don't have years to be able to pour into training new people. Many people don't understand that precision welding is exacting work that can't be learned on the job in a week. The craft takes patience, precision and above all practice. Accelerating technological change is driving demand for high level skill sets.
Education and training always have been a gateway to opportunity. But today there seems to be a mismatch between the skill businesses are demanding and the skills that applicants are bringing to the table [10]. The overall lack of knowledge and quality in the welding workforce has reached staggering proportions. We have a large and growing skills gap that must be addressed urgently.
10. SOLUTIONS TO THE WELDER SKILL GAP
a. Welding as a viable carrier path. Improving the image of welding so top students will be drawn to the industry and bettering training methods for welders and welding engineers are the keys to welding’s future [4].
b. One common misconception all the educators want to dispel is the myth of “once a trade person, always a trade person.”
c. For the workforce to become the key to success, the work place must become a learning environment. Whatever may be the degree of modernisation / automation in welding, a knowledgeable and trained workforce is a must for success in any manufacturing organisation. A workforce that is appropriately educated at all levels will drive a technological revolution in welding for this country.
d. Welders need to be rewarded for the “net quality” output not their “gross” output, with the emphasis on quality not quantity or speed. Because customers want quality [11].
e. Want welders? Pay them. “Even when things change, something stay the same.” Until the industry realizes that the problem it has is due to the low wages they offer, they likely will never find enthusiastic or qualified welders [12]. It isn’t a shortage of skilled welder, it’s a shortage of welders willing to work for poor wages, poor working conditions and poor benefits. Ensure a safe and healthful working environment for workers. Among others, the following actions can help ease this burden:
10.1 Work Hard to Retain Your Employees
Employees have choices. Those with the skill have a buffet of compensation and workplace offerings.
• You offer competitive wages and benefits
• To create an environment in which they want to work nowhere else but your company. When employees feel comfortable in the workplace, they are more likely to stick with you.
• Respect for people and operating with humility
• Managers and supervisors may need to share some of the decision-making authority.
• Empower employees to act. Their ideas need to be reasonable, of course.
• Invest in education and training, offer job rotations.
• If companies couldn’t find existing welders, train hardworking
individuals with an aptitude for working with their hands to become welders. Find the right people who had a desire to learn. Teach those inexperienced individuals to be able to weld and to do it correctly and safely. People become more loyal to you when you invest in them [14].
Meanwhile, the company gets less turnover, more satisfied employees and actionable improvement input. It is hard work, but the upside is worth it - and the cost of doing nothing might be devastating [13].
CONCLUSION
New materials are creating a greater need for a highly educated and innovative welder workforce. The future of welder training is in jeopardy because we lack the number of enrolments and completions required to address the shortage in the industry. The needs of the society are constantly changing and hence the curriculum should also be dynamic. When ITI technical training is completed, a minimum of 6 years in the occupation is required for mastery of skills. NCVT has its own training curriculum with the guidelines to assessment that have been adapted by ITI’s. We need to totally revise the NCVT education system in India to acknowledge the Welder Trade as an acceptable alternative for students. One immediate thing that the All India Council for Technical Education and other authorities should do is to crackdown on colleges to ensure that 60% of marks for admission.
In Summary, Innovation and investment in technologies won't work without a capable workforce. Investing in technologies without skilled welders is ineffective at best and highly disruptive and unproductive at worst. It means we will see and evolution rather than a revolution of joining. We commit ourselves to this mission, to advance the science, technology and people of welding, for ourselves and for the next generations. The image of our future welders should be knowledgeable and skilful.
REFERENCES
1. Patricio F. Mendez, The joy of welding, AWS Welding Journal, October 2018, page 28,30
2. Hal Stacey, In the beginning…. – AWS Welding Journal, June 1994, page 46.
3. K. Suresh Kumar, Training and certification in welding – WeldFab Tech Times, April – May 2018, page 53.
4. Andrew Cullision and Mary Ruth Jhonson, Welding forges into the future – AWS Editors
5. Curriculum – Welder – developed by Central Staff Training and Research Institute CSTARI, Kolkata.July 2022 NSQF Level-3.
6. Phil Evans, Letters to the editor – AWS Welding Journal, December 2005, page 19.
7. Shilpa Vasudevan, Education tours to facilitate learning – EDEX Indian Express daily newspaper 23 December 2013.
8. Rhea Gill, Weld training for breadth and depth – Canadian Fabweld, November 2019, page 45.
9. Randy Hoffman, Sharing thoughts about the image of welding – The World of Welding, Hobart Institute of Welding Technology.
10. Steve Odland, How to close the skills gap – www.etcnbc.com, 3 March 2016.
11. Robert W. Messler, JR, Seven truths for welding and joining education – AWS Welding Journal, February 2014, page 17
12. Jeff Sipes, How metal fabricators distinguish themselves – The FABRICATOR, January 2022, page 33
13. Amanda Carlson, No welders? No problem-The WELDER, Nov/Dec 2021, page 22, 23.
ACKNOWLEDGEMENT
The author would like to give a special acknowledgement to Mr K. Venkatesan and Mr. S. Manikandan for their cooperation. The author is indebted to the host of colleagues and students with whom he has associated during the past 15 years for valuable discussions on welding and joining.
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