Transition to automation, easy decision. Adding weld robotic

Transition to
automation,
easy decision.
Adding weld
robotic
automation to
your operation.
Experience to Serve
Joe Dengel – Weld
Robotic Specialist
Chris Boycks – Director
of Quality and Process
Improvement
Experience to Serve
Veteran-Owned
Small Business
More than 57 years of
Metal Fabrication
Serving over 50
different Industries
Experience to Serve
True Job Shop – Military to
Food Grade and Medical
Prototype to full production
80 full time employees with
3 shifts – Monday through
Thursday with 4, 10 hour
days and a weekend shift of
3, 12 hour days
Commitment to serve…
Original Building –
1955-1968
1968-1979 Location
1980 -- New Location
2005 -- Expansion
Atlas Logistics Facility
Warehousing in logistics facility to support
Kanban / JIT / Lean Manufacturing
Expansion 53,000 Sq.ft.
WhatCommitted
are wetocapable
of doing
you……..
growth/increased
servicesfor
despite
economy
Lasering / Punching
Amada 4000 Watt Rotary Laser
round, square, rectangle tube cutting, angle & channel
material size .75” – 8.66” (round/rectangle diagonal)
New Amada Automated Material Handling Station
with 15 shelf tower system
Amada 6000 watt laser
Multiple Amada 4000 watt lasers
Amada Vipros Turret Punch
Amada Coma Turret Punch
Whitney 1548 Punch
Whitney 360 Punch
Click on image above for a short video of our Rotary Laser
Forming / Tube Bending / Rolling
New Amada 243 ton –
CNC controlled with quick change dies / 14’ bed, 5-axis back gauge
Horn CNC Multi-axis Automatic Tube Bender
Multiple Cincinnati Auto form CNC Press Brakes
WDM Workhorse 4 roll pinch roller
Quality
- ISO 9001: 2008 Certified
- AWS Sustaining Member
- Multiple portable FARO CMM’s
up to 8 ft. of measuring capability
- Six Sigma Green Belt on Staff
- DMAIC Process
- 3 in-house AWS CWI’s
Full Service
-CNC Marvel Spartan S620A saw
-Acra AM3 Milling Machine
-Flex Arm Tapping
-Shearing up to 10” and .25” thick
-Numerous deburring/ material finishing methods
-Certified Solid Works / PEP nesting software
-DXF, DWG, HPGL, PDF, STP and TIF File ready
-Large and Small assembly
-Well-maintained warehousing to support Kanban/JIT/Lean
manufacturing systems
-Powder coating, wet paint, vinyl dipping, e-coating, anodizing,
tempering and hardening
-Reliable and convenient transportation methods, including Jay trucking
Welding
Multiple Panasonic Perform Arc Robotic Systems
Low, mid or high
volumes of manufacturing into single or
progressive fixtures
Certified Welding
--AWS D1.1 and D1.3 – Steel
-AWS D1.2 / D1.2M- Aluminum
-AWS D1.6/ D1.6M – Stainless Steel
-AWS D8.1M / D8.7M - Resistance Spot
Welding
-GMAW, GTAW, SMAW, FCAW
-NAVSEA TECH PUB 271/248
Click on image above for a short video on our
Panasonic Robotic Systems
BLUCO Modular Fixturing for robotic
systems and manual welding stations
Weld Qualifications / Testing
-Many WPS and
PQR’s ranging all
material types, pre
qualified and not pre
qualified.
- Guided bend testing,
Macro Etching,
Tensile pulls with
elongation data , and
Annealing all done in
house.
Why Weld Robotic Automation?
Dollars and Sense
Process/People vs. Machinery Ability
-Customer need vs. people hours available
-Volume of work vs. capacity, 1- 1000
- Cost driven, carrying costs per year vs. employee
(R.O.I.)
- Plug and play, 4- 6 weeks vs. hiring
process/training
- Minimal training to get “operator” up to speed
Why Weld Robotic Automation?
Dollars and Sense
Process/People vs. Machinery Ability
-
Consumables - Consistent Usage
Consistent flow – Repeatable Part Design
Welding takes in optimal weld position
Change overs take place in minutes, torch change
outs, etc…
- Robotics rarely takes extra breaks or calls in sick
Improved Quality
o Weld sizes will not
vary.
o Welds wont be over
looked or forgotten.
o Every part will look
the same as the last.
The robot will only
do what you tell it
to.
Success with Robots
o Robots output has proven to be 3 to 1 compared to a manual
welder.
o The addition of robotics has increased thru put velocity, across
3 shifts.
o Quote jobs at competitive prices.
Fixtures
2 types
Permanent and Modular Fixturing
o Permanent Fixtures
o Large Heavy items
o Odd shapes
o Multistep / Progressive
Modular Tooling
o Multiple part #’s can run at the same
time.
o Makes it easy to change the quantity.
o Allows you to do low quantity jobs
without large setup times.
Touch Sensing
o One of the biggest eliminators of down time
o Keeps manual touch ups to a minimum
o Robot self adjusts its program to the part
o Helps in running multiple batches of parts where the
dimensions vary slightly from batch to batch
o Corrects the difference between the 3D offline world and real
world
o Reduces scrap
Offline Programing
o No down time to write new
programs
o Get new parts ready to go on
the robot before the work
ticket hits the floor.
o Makes it easier to shuffle
programs around to free up
space and run more than one
part per side.
Advantages
o Quoting and Scheduling are more accurate with solid weld
times.
o Touch sensing allows for upstream variability in sub
components.
o Weld consistency the same, they don’t vary visually based on
who welded them.
o Consumable usage more predictable and better controlled.
o Run multiple jobs at the same time.
Looking Forward to our Future
Thank you