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May 2026

Starsolver™: The Proven Method to Increase Welding Productivity and Reduce Fabrication Costs

Boost welding productivity and cut operating costs with Starsolver™. Learn how Linde’s data driven workflow optimization transforms fabrication performance.

Modern Fabricators Are Losing Productivity — Here’s Why

Across most fabrication shops, labour and overhead represent 85% of total welding costs, while materials account for only 15%. That means the biggest productivity opportunities are hidden inside the workflow itself — not in the raw materials.

Small inefficiencies compound into major costs:

  • Defects / Rework
  • Waiting / Downtime
  • Post weld Clean up
  • Overprocessing
  • Lack of Automation
  • Incorrect gas supply mode
  • Process variation

Starsolver™ uncovers these bottlenecks quickly and delivers fast, measurable improvements that often require no capital investment.

How the Starsolver™ Optimization Process Works

The program follows a five-step methodology proven to improve throughput without disrupting production:

1. Evaluate the Entire Workflow (Low Disruption)

A specialist conducts a full walk-through of your welding and cutting operations — from material handling to final inspection — with minimal impact on production.

2. Measure Real Production Parameters

Starsolver™ records critical data including:

  • Travel speed
  • Duty cycle
  • Gas usage
  • Weld size
  • Wire feed speed
  • Cutting parameters
  • Operator efficiency
  • Power consumption

3. Analyze the Root Causes of Waste

Linde’s Metfab Productivity Specialists (MPS) quantify your losses by measuring:

  • Rework
  • Rejects
  • Post weld cleanup
  • Changeover time
  • Setup delays

4. Improve With a Prioritized Action Plan

You receive a simple, clear list of the highest impact recommendations — often involving process changes, gas optimization, or parameter tuning, not new equipment. Linde reports that this approach consistently delivers throughput increases and cost reductions across materials, labour, automation, and gas delivery systems.

5. Follow Up to Ensure Gains Stick

After implementation, Linde’s specialists return to verify results, fine tune parameters, and ensure long-term performance improvements.

Why Starsolver™ Outperforms Traditional Productivity Programs?

Led by Metfab Productivity Specialists

These experts bring decades of experience in welding, CNC cutting, laser systems, hard automation, robotic welding, and gas delivery optimization — making the program highly specialized and hands-on.

Cost Reductions Without New Equipment

Starsolver™ recommendations typically involve process optimization, not capital purchases — which is essential for shops trying to maximize.

Backed by Real Production Data

Unlike generic audits, Starsolver™ bases every recommendation on measured parameters collected directly from your machines and operators.

Designed for Full-Scale Fabrication Operations

Starsolver™ addresses every element of the workflow, including:

  • Gas analysis
  • Gas-to-wire ratios
  • Supply modes
  • Weld parameters
  • Cutting processes
  • Deposition efficiency
  • Duty cycle optimization

Frequently Asked Questions

How does Starsolver™ actually improve welding productivity?
Starsolver™ identifies inefficiencies by measuring real production parameters — such as weld travel speed, gas usage, wire feed speed, and operator duty cycle — then delivers an actionable plan to remove bottlenecks and increase throughput.

Does Starsolver™ require new welding or cutting equipment?
In most cases, no. Linde notes that Starsolver™ improvements typically come from process, material, or parameter optimization, not capital investments in new equipment.

How much can Starsolver™ reduce costs?
Depending on your operation, Starsolver™ can reduce labour and overhead costs by up to 10–20%, supported by real field results recorded across many fabrication shops.

What types of shops benefit from Starsolver™?
Shops that perform welding, cutting, automation, or metal fabrication — including OEMs, job shops, and high volume manufacturers — see strong results from Starsolver™ deployment.

How long does it take to see results?
Most shops begin seeing measurable improvements quickly, and ROI typically appears within weeks to a few months.

Ready to Unlock Hidden Productivity in Your Shop?

Booking a Starsolver™ evaluation is easy: