From 8-10 Gates/Hr to 11-13 Gates/Hr + Improved Quality
“Colewell came in early and stayed late, they made the delivery process quick, and they stayed to train all of our people.”
– John Bavestar / Operations Manager, Hutchinson Inc. HW Brand
Challenge:
Hutchison Inc. (HW Brand) has been in business for over 70 years and has grown to become a top manufacturer of products for livestock and equine such as fencing, wire, baling supplies, and building materials. In order to keep up with demand and given the shortage of welders in our area, they looked to automation.
Being completely new to robotics, Hutchinson wanted to work with an integrator who was local to their area that they could rely on before, during, and after the delivery process. It was important to find someone with a good reputation in robotics and experience in welding automation.
The production line they wanted to automate was welding a light gauge round steel, which is a very difficult process. And of course, they needed a system that could do the job at least as efficiently as their skilled welders with high quality and low defects.
“Colewell spends time with you before the project starts to figure out how you work, then builds the product for you, and then helps you program it.”
– John Bavestar / Operations Manager
Solution:
We designed their cell with two Fanuc welding robots utilizing Lincoln welding equipment with an STT option in the center that would alternate between two fixtures on either side. While the robots are working on one side, the 2-person welding team can unload and reload the other side.
In order to truncate our lead time and get this system up and running quickly was using simulation software to lay out the cell, design the program, and run cycle time analysis. This shortens the build process on our shop floor as well as the installation at their facility, limiting downtime as much as possible.
Once the system was installed, we worked closely with the welding team to make final adjustments and work through any issues they had in order to ensure the highest quality welds every time.
“Colewell has made life easier for us by their willingness to come in and make any adjustments to the jigging to make our process easier. And then also stay again, and help train the employees and bring them up to speed on any changes that they have made.”
– John Bavestar / Operations Manager
Results:
With the new robotic welding cell Colewell designed, built, and installed, Hutchinson was able to increase their gate production from 8 to 10 per hour to 11 to 13 per hour.
Not only that, but the welding staff is not having to put in as much overtime and they’re having fun with the robots! They enjoy using their problem-solving skills to keep making the process even better.
They’re also getting more consistent welds, higher-quality finished products, and far fewer defects.