- Industry
- Vehicle components
- Year
- 2024
- Scope
- PLC and controls, Machine safety, Systems integration
- Platforms
- PLC, HMI, T-slot aluminum guarding
Problem
Every part at this cell was welded by hand, so the station needed a skilled welder for repetitive work, at a skilled welder's rate.
Approach
The manual cell was replaced with an automated one:
- PLC and HMI control for the whole cell
- Custom PLC programming with part recipes: the operator picks the part on the HMI, and the cell loads the settings for it
- T-slot aluminum guarding around the cell
Result
- The station now runs with a machine operator instead of a welder, at a lower labor rate
- Cycle time cut by 18%
- More repeatable welds from part to part
- The welder is free for skilled work elsewhere in the shop
More projects
-
Vehicle components · 2026 · In progress
A pneumatic assembly machine lost too much cycle time every time its light curtain tripped. The safe stop was redesigned to hold position instead of dumping air, at the same safety level.
-
Manufacturing · 2026 · In progress
A PLC- and HMI-controlled leak test cell, specified so the client knew exactly what they were buying and how it would be accepted.
Have a machine or line that needs work?
Send a short description of the problem. We'll set up a call to talk it through.
Start an inquiry
