A provider of precision sub-contract fabrication services, KME produces a vast range of components used in a number of industries, through the process of MiG welding. Historically this process had been solely undertaken by a human operative, though in a bid to continue to operate when experiencing difficulties recruiting skilled staff, an automated robotic cell was implemented. After consultation with KUKA integrator Bauromat - automation experts who develop welding cells for all manner of industrial applications – a design to KME’s manufacturing requirements was agreed and executed.
Previously, materials were welded by hand and each cycle took between six and eight minutes. Having automated the manufacturing process, KME achieved cycle time savings of around 65%, a reduction of five minutes. Quality output was also a consideration when deciding to automate, which was maintained on each cycle.
Bauromat worked closely with KME to identify the most suitable robot model that could undertake the welding requirements critical to their operational success, and the KR6 R1820 from KUKA, designed specifically to operate within an arc welding application, was chosen.
A Fronius TPS 400i weld set was chosen as the end effector to power the MIG welding process. Utilising the latest KUKA software, the KUKA robot would stitch weld parts using 1mm wire while the turntable has the capability of moving the part in coordination while parts can be loaded and unloaded during the cycle. Tip dressing and cleaning within the application can also be attended whilst the turntable rotated, further supporting an increase in product output through improved cycle times.
In addition to the KUKA robot controller, the system was integrated with a touchscreen HMI (human machine interface) connecting the operator to the real-time system information. Each aspect of the system can be scrutinised to ensure optimum performance and deliver a seamless manufacturing experience.
The system affords KME with many benefits, notably the ability to continue to manufacture using a process into which they are finding it challenging to recruit. They are able to achieve significant cost savings through an increase in cycle time, resulting in increased product throughput, whilst maintaining a quality of output. It also enables KME to offer existing staff members the opportunity to learn new skills, training key personnel to become robot programmers and/or technicians.
There will always be a need for skilled labour, but the adoption of automated robotics can address the skills gap within manufacturing and provide opportunities for our millennials.
Robotics are being adopted more and more within what we would call traditional manufacturing processes. Technology has significantly changed the factory environment of even a generation ago. Modern manufacturing today requires an unparalleled degree of technical awareness, trouble shooting and problem‐solving skills as new employees are instead required to manage, repair and programme automated systems. With staff upskilled and trained with new skills, it leaves the robot to do the work at a more consistent and productive level, making automation a better solution for all involved.
