MAR keeping jobs in Australia
A respected Australian manufacturer of heavy duty trailers and specialised transport equipment was faced with a difficult task– they needed to increase productivity and output in Australia while minimising costs. Failure to achieve specified targets would see them being forced to take the manufacturing process off shore or alternatively import finished product from So
uth East Asia.
Machinery Automation & Robotics (MAR), was selected to design and install a robotic welding solution capable of handling a range of welded components. The project had two goals – improve productivity immediately utilising current design and build, while delivering a platform that is flexible, enabling them to make further productivity gains down the road as they redesign their products to take advantage of the automated robotic welding technology.
The final design, after extensive R&D and testing, proved to be simple yet technically advanced as it integrated the ability for the cell to run in full automated mode, yet be intelligent enough to allow manual input via a Manual Jog Station. The design had several physical challenges to meet as well - being the need to continually reposition extremely heavy product as well as adding components during the assembly.
The final design consists of a welding robot on a travelling track that covers two stations, One single axis rotating positioner that can hold up to 2000kg is in one station, while in the other station is a dual axis positioner that can hold up to 750kg of product to be welded. The whole robot station needed a safety system including fencing that enabled the stations to be isolated individually. In addition the programme software needed to have the flexibility built into it for manual intervention as well as having a user-friendly interface that enabled the operators to change parameters as the products changed.
The two stations sequentially weld differing component sizes, however what has made the cell unique is that there is a Manual Job Station that enables more parts for station 1 to be loaded while station 2 is actually welding. As the parts are loaded the positioner can also be rotated manually. This allows seamless processing of product as well as flexibility, including the opening of the interconnecting gate between the stations to weld longer parts.
The manufacturer experienced significant improvements immediately following installation and commissioning.
Increase in Productivity & Product Quality
As well as the welding process being time consuming, a large number of the products produced required machining following manual welding due to the twisting and distortion caused by the weld.
The manufacturer have recorded more than 60% reduction in manufacturing time for their welded components as well as a 26% reduction in machining time due to consistency of product, with no twisting or distortion of welds. The cost savings based on the time saved alone is extremely significant.
Consequently, as a result of the new automated welding system, the company has experienced a large increase in production, What used to require the operation of 3 or 4 welders per bay with 2 shifts running back to back, is now completed with the one welding cell. Staff can load one bay station whilst the robot welds in the other, allowing the robot to operate efficiently and accurately without interruption.
Reduced Resources
Reduction in labour costs is not limited to welding personnel only. The 2 positioners that are incorporated into the welding system have enabled large and heavy components to be welded without the requirement of a crane to rotate and reposition product. This does three things – it not only removes the need for double handling of the product saving a huge amount of time, it also reduces the staff that were continually involved in locating available cranes plus an operator, as well as the requirement of having cranes available to lift and rotate the necessary parts during the welding process.
Reduced OH&S Risks
By limiting the use of cranes to loading and unloading, staff no longer are involved in the rotation of the heavy parts that are held up with the crane. This has significantly improved workplace safety by completely eliminating the safety risks during the rotation process.
Saving Jobs
Although there has been a reduction of staff as a result of the installation of the new, robotic welding system, it has enabled the business to remain competitive and consequently remain operational in Australia, thus preventing the loss of many more staff including design engineers, who are still involved in the manufacturing process.
Machinery Automation & Robotics
NSW Head Office:
(61) 2 9748 7001
Melbourne Office: (61) 3 9335 4344
Brisbane Office: (61) 7 3348 9110