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Sector: Automotive Supplier
Robotic Welding Cell with Seam Tracking (Sample Case)
Conversion of a manual welding station suffering high scrap due to part-tolerance variation into a robotic welding cell with real-time seam tracking.
Challenge
Part variation at the customer’s manual welding station caused inconsistent seam quality and a high rework rate; production targets could not be met with existing capacity.
Our Approach
The cell layout was validated in simulation, and cycle time analysis drove robot and positioner selection. A real-time weld seam tracking system was integrated so part tolerances are compensated automatically along the path. Installation was completed during planned stops with zero disruption to ongoing production.
Results
- Significant reduction in rework rate (target: zero defects)
- Measurable cycle time improvement
- Operators redeployed to higher-value work
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