Case Study

Hutchison Inc. Boosts Production with Launch of Robotic Welding

Hutchison Inc. (HW Brand) has been in business for more than 70 years, manufacturing fencing, wire, baling and building material products for livestock and equine. But it wasn’t until recently – when a workforce shortage made keeping up with demand difficult – that the company considered automation. New to robotics and navigating a challenging welding production line, Hutchison turned to Iowa-based Colewell Automation to develop an integrated robotic solution that not only improved consistently high quality but increased production and reduced worker overtime.

Results

Fully automated process ensures more consistent welds, higher quality finished products and fewer defects
Increased employee satisfaction and less need for overtime
Increased steel gate production by at least 37% per hour

Story

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.”

We wanted to weld a hard to weld product at the same pace, and quality, that our skilled welders do upfront matching matching the daily output that they have with, quality and low defects.

John Bavester

Operations Manager, Hutchison Inc.

FANUC Products Used

ARC Mate Series

Meet Colewell Automation, FANUC Authorized System Integrator

At Colewell Automation, people come first. And when we all work together, we can do anything. As a FANUC and Lincoln Authorized Robotic/Systems Integrator, the Colewell team brings passion, curiosity, and determination to provide turn-key and custom automation systems, robot programming, production improvement, and fast, personal customer service to manufacturers across the Midwest and beyond.

Visit Colewell Automation

About Hutchison Inc. (HW Brand):

Hutchison Inc has been in business for over 70 years. Once a small moving business it has grown to become one of the top manufacturers and distributors of livestock and equine equipment, fencing and wire products, baling supplies, and lumber and building materials. We take pride is serving farm and ranch stores, rural farm cooperatives, lumberyards, implement stores, and hardware dealers throughout rural America. Over the years the company has expanded, creating a total of five divisions: Hutchison Western; Hutchison Lumber and Building Products; HW Brand Manufacturing Company; Hutchison Transportation; and Logan Valley Manufacturing.

Learn More about Hutchison Inc.