In the face of a nationwide welder shortage, it is imperative for fab shops to keep up with the latest innovations in the industry. One such innovation that has garnered significant attention is robotic welding. But, before deciding whether or not your fab shop should adopt automation technology, it's crucial to understand what robotic welding entails, the benefits it offers, the challenges it may pose, and the real-life success stories of its implementation. Let's dive in and explore the world of robotic welding.

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Understanding robotic welding

What is robotic welding?

Robotic welding is a process that utilizes robots to perform welding tasks, including TIG and Spot welds. Unlike traditional welding, which relies solely on manual labor, robotic welding combines the precision and accuracy of machines with the comfort and safety of human supervision. 

The majority of fab shops will use robotic stationary robotic arms, while some may adopt gantry robots which can move along a fixed trajectory. These robots are equipped with welding end-effectors which can be programmed to perform different welding techniques, such as MIG (Metal Inert Gas) welding, TIG (Tungsten Inert Gas) welding, or spot welding.

The benefits of robotic welding in a fab shop

Increased productivity and efficiency

Robotic welding offers several efficiency improvements over manual welding. Firstly, robots are capable of working at a much faster pace - they don’t stop even to wipe sweat from their brow - resulting in increased productivity. Secondly, robots can perform repetitive tasks with consistent precision, ensuring high-quality welds every time. This eliminates the risk of human error and reduces scrappage and the need for rework.

In the face of a US welding labor shortage, the ability of one welder to oversee multiple welding robots can help your fabrication shop keep up with demand and reduce fatigue. Unlike humans, robots are not slowed by hot, smokey environments and can clamp difficult parts with tricky geometries in place.

Improved weld quality

Robots are programmed to perform welding with exceptional precision, ensuring consistently high-quality welds. Unlike human welders who may experience fatigue or inconsistencies in technique, robots maintain a consistent approach throughout the welding process. 

This allows a fab shop to maintain stringent quality control standards, reducing the chances of discontinuities and reducing their scrap rate. By achieving consistently superior welds, fab shops can easily position themselves as a precise and reliable manufacturer in their local market.

Enhanced worker safety

Worker safety is a top priority in any fab shop. Manual welding poses various risks to workers, including exposure to hazardous fumes, intense heat, light beams and sparks. These risks are significantly reduced with automation.

By automating the welding process, fab shops can minimize the exposure of workers to these hazardous elements, resulting in a safer working environment. Given the challenges of recruiting welders, the benefits of being able to promote a safer working environment speak for themselves. Reduction in workplace accidents and insurance claim costs may be factored into your cost-benefit analysis (more on that later).

Beyond a safer working environment, the implementation of robotic welding technology opens up opportunities for upskilling and reskilling your workforce. As robots automate repetitive and mundane tasks, human welders can focus on more complex and intricate aspects of fabrication or tackle more complicated products. Investing in the training and development of employees allows fab shops to create a skilled workforce that is ready to take on new challenges and adapt to evolving industry demands.

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The challenges of implementing robotic welding

While the benefits of robotics are evident, there are several challenges which keep every fab shop from implementing automation. Let's explore some of these challenges in more detail:

High initial investment

Acquiring robotic welding equipment and implementing the necessary infrastructure can be a substantial financial undertaking for smaller fab shops. The cost of purchasing the robots, setting up the welding cells, and integrating them into the existing production cell can be significant.

Costs will include installation, programming and necessary equipment like an end-effector purposely chosen for your chosen parts or task. Additional costs can include safety equipment specific to your application, or accessories like conveyors.

6-axis robotic arms, the most common type of robot used to automate welding, typically start from over $40,000, although our welding-capable RO1 robot starts from $5/hour. 

It's crucial to consider the long-term return on investment, which often outweighs the initial costs. In your cost-benefit analysis, make sure to factor in the obvious gains in productivity and output, but pay attention to the less-obvious benefits like a significant reduction in scrappage, a reduction in health-related leave amongst your welders and the ability to differentiate your offering on the market. Over time, the cost savings and increased revenue generated by robotic welding make for a very viable option in many fab shops.

Training and skill requirements

Introducing robotic welding into a fab shop requires adequately trained personnel who can program, operate, and maintain the robots. While the robots themselves are designed to be user-friendly, there is often still a learning curve involved in mastering the technology. The workforce needs to be trained in robotic welding techniques and familiarized with the specific programming language used by the robots.

Some robots, including the RO1, can be programmed without the need for coding knowledge, thanks to visual, drag-and-drop routine builders. Choosing a robot with this capability can significantly cut down training and retooling times.

Despite this simplicity, specialized training programs may be necessary to ensure that your workforce is proficient in specific robotic welding considerations, troubleshooting steps, safety protocols and basic maintenance.

Often, your implementation partner or robot manufacturer will be able to provide support or materials for training.

Maintenance and repair considerations

Robotic welding systems, like any other machinery, require regular maintenance and occasional repairs. Fab shops need to allocate resources to ensure the proper upkeep and timely repairs of their robotic welding equipment. A well-defined maintenance plan should be put in place to address routine maintenance tasks, such as cleaning, lubrication, and inspection of the robots and welding cells.

Given the extreme temperatures and conditions welding robots work in, occasional repairs may be necessary due to component failures or wear and tear. Fab shops should have a contingency plan in place to minimize downtime in the event of a breakdown. This may involve having spare parts readily available or working with a service provider who can respond quickly when a failure occurs. 

Downtime is an important component to factor into your cost-benefit analysis. Robot manufacturers will be able to tell you the average number of operational hours before a failure is expected. Often, robot manufacturers will also offer expedited part replacements at cost or free of charge to keep your robot cycling over.

Case studies of successful robotic welding adoption

Company A's transition to robotic welding

Company A, a medium-sized fab shop, was facing escalating production costs and quality control issues during the 2020 pandemic. They decided to invest in robotic welding technology and found immediate improvements. With the help of robots, they accomplished a 40% increase in part fabrication rates and a staggering 60% reduction in scrappage. Combined, these changes made a significant contribution to their bottom line and quickly covered the initial investment costs.

How company B improved consistency with robots

Company B, a large fab shop, struggled with consistency in its manual welding process. Having a large team of welders with different levels of skill and experience meant that they struggled to ensure a consistent level of finish. They implemented robotic welding systems, using a six-axis robot with a high level of repeatability and experienced a significant transformation. Through automation, they achieved not only a 20% reduction in production time but managed to ensure a uniform weld quality across all their products. Consequently, Company B strengthened its market presence and established itself as an industry leader.

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Making the decision: Is robotic welding right for your shop?

Now that we’ve covered the benefits, challenges and industry experiences of automating welding in your fabrication shop, here are a few considerations to help you decide whether this technology is right for your shop.

Evaluating your shop's needs and capabilities

Before making a decision, it is essential to analyze your fab shop's specific needs and capabilities. Assess factors such as production volume, product complexity, and labor costs. Determine if your shop can benefit significantly from the increased productivity, improved quality, and enhanced safety that robotic welding offers. Understanding your shop's unique circumstances will help you make an informed choice. 

It’s also worth paying attention to the physical environment of your shop. Do you have the space for multiple robots to operate? Do they need to operate in close proximity with humans? These factors can affect the total initial investment size required to ready your shop floor for automation.

Calculating the potential return on investment

While the upfront costs may seem staggering, calculating the potential return on investment (ROI) can paint a clearer picture. Evaluate factors such as increased production output, labor cost savings, reduced rework, and improved customer satisfaction. By quantifying the potential benefits against the investment required, you can better assess the financial viability of adopting robotic welding in your fab shop.

Considering the future of the welding industry

Lastly, it's crucial to consider the future trends and developments in the welding industry. Robotic welding technology is continually advancing, offering even greater capabilities and opportunities for fab shops. At the same time, US welder shortages mean the industry is facing some of the greatest supply shocks in recent history. By embracing this technology early on, your fab shop can position itself as an industry pioneer, ready to adapt to the changing demands of the market, handle increasing levels of demand and secure long-term success.

The decision to adopt robotic welding in your fab shop is not one to be taken lightly. Understanding the fundamental aspects of this technology, as well as the potential benefits and challenges, is vital for making an informed choice. By studying real-life case studies and thoroughly evaluating your shop's needs and capabilities, you can determine whether robotic welding is the transformative step your fab shop needs to take.

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Next steps

Interested in bringing robotic machining to your own business? RO1 by Standard Bots is the best choice for machine shops large and small:

1. Affordable: RO1 is the most affordable robotic arm in its class, starting at almost half the price of incumbent competitors. 
2. Powerful: RO1 is faster and more precise than competitors, despite having the highest payload capacity in its class at 18 kg.
3. Integrated: RO1 comes equipped with built-in relays to control almost any machine on the market, including plug-and-play support for Haas CNC milling machines.
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Speak to our solutions team today to organize a free, 30-day onsite trial and get expert advice on everything you need to deploy your first robot.