Facing a workforce shortage and struggling to meet demand, livestock and
equine product manufacturer Hutchison Inc. turned to automation to address a
particularly difficult welding production line for their steel gate
products.
To ensure that they had access to on-site support before, during and after
the delivery process, first-time robotics user Hutchison Inc. relied on
Colewell Automation in central Iowa to develop a solution that could match
the high-quality work of their skilled welders.
To minimize lead time and get the system up and running as quickly as
possible, Colewell Automation used simulation software to design a
dual-sided cell with two FANUC robots and Lincoln welding equipment. With an
STT option in the center that alternates between fixtures on either side,
the robots are able to work on one side while a two-person welding team
unloads and reloads the other side of the system. By using simulation
software to design the cell, both the build time and installation process
was shortened, resulting in as little downtime as possible.
With the automated system in place, Hutchison Inc. has increased gate
production from 8-10 per hour to 11-13 per hour, an hourly increase of at
least 37 percent. In addition to this, finished products feature more
consistent welds and higher quality overall, with far fewer defects.
According to Breanna Anderson, robotic welding team leader, the team is
enjoying not only the process, but “using problem solving skills and welding
skills to get things moving and grooving again.”