Overview
A Manufacturer’s Quest for Efficiency
A stainless-steel piping manufacturer in the ACT was struggling to keep up with changing production demands while still meeting high-quality standards. They handled many small-batch jobs, different pipe sizes, and tight deadlines, so they needed a solution that could keep up with their fast-paced work.
Enter Infinite Robotics, with a mission to revolutionise their welding process and future-proof their operations.
The Challenges
A Perfect Storm of Pressures
The manufacturer faced several challenges that could disrupt their operations:
Tight Deadlines
Customers wanted fast project delivery, so even small delays could lead to missed deadlines and unhappy clients.
Labour Shortages
Like many others, they had trouble finding and keeping skilled welders, which made it hard to keep production steady.
Quality Concerns
Because they often switched between different parts, there was a higher risk of uneven weld quality and expensive rework.
Operator Fatigue
Doing the same welding tasks over and over was tiring for workers, which lowered both efficiency and morale.
With so much at risk, the company needed a solution that could solve these problems and help them succeed in the long run.
The Solution
Flexibility Meets Precision
To solve these challenges, Infinite Robotics provided the FlexWeld Dual-Station Cobot Welding System. Made in Australia, this system gave the manufacturer the flexibility, speed, and accuracy they needed to stay ahead.
Here’s why this solution was different:
Collaborative Robotics
At the heart of the system was the FANUC CRX10iA/L collaborative robot, integrated with a Kemppi AX Pulse MIG welding system. This combination ensured precise, high-quality welds for stainless steel pipes.
User-Friendly Programming
The easy-to-use interface lets operators quickly adjust jobs, so they could start using the system right away.
Dual Workstations
With two workstations, operators could load parts on one side while the cobot welded on the other, which reduced downtime and increased productivity.
Siegmund Welding Benches
Two Siegmund welding benches (1500mm × 1000mm) gave a flexible and reliable setup for jigs, helping ensure consistent results.
Quick-Swap Fixtures
The system allowed for fast part changeovers, making it perfect for high-mix production.
This solution did more than meet the manufacturer’s immediate needs; it helped them compete and grow in their market.
Key Features & Capabilities
What Sets FlexWeld Apart
The FlexWeld system offered several key benefits which include:
Consistent High-Quality Welds
The system provided precise, repeatable welds, which lowered the chance of mistakes and rework. The system allowed operators to switch between jobs with minimal downtime.
Optimised Cobot Reach
The FANUC CRX10iA/L worked well for small to mid-size pipe welding, making it useful for many different jobs.
Reduced Operator Involvement
Automating repetitive tasks helped reduce worker fatigue and let staff focus on more challenging work.
Implementation
Seamless Deployment, Immediate Results
A key advantage of the FlexWeld system was how easy it was to set up. Here’s how it worked:
Pre-Build & Testing
The system was built and thoroughly tested at Infinite Robotics’ Sydney workshop, so it was ready to use right away.
Rapid Installation
Installing the system at the customer’s site took only one day, causing very little disruption.
Operator Training
Operators learned to use the system in just half a day, thanks to the easy-to-use programming interface.
Just hours after installation, the manufacturer was already welding production parts and seeing the benefits of the new system.
The Results
A Game-Changing Transformation
The FlexWeld system made a big difference for the manufacturer. Here’s what they achieved:
40–60% Reduction in Production Time
The system sped up output by 40–60%, depending on part size, so the company could meet tight deadlines more easily.
Upskilled Workforce
Operators learned new skills, which improved their job satisfaction and future opportunities.
Lower Rework Rates
Consistent weld quality meant fewer mistakes, less waste, and less rework, which saved time and resources.
Reduced Operator Fatigue
Automating repetitive tasks made work easier for operators and improved morale.
Increased Daily Output
With the dual-station setup, the company could make more parts each day without hiring more staff.
These results not only solved the manufacturer’s immediate problems but also helped set them up for long-term growth and success.
Suitable Applications
Versatility in Action
The FlexWeld system works well for many different uses, including:
General Manufacturing & Job Shops
Great for businesses with a variety of production needs.
High-Mix Fabrication
Built to handle frequent part changes and different job requirements easily.
Whether you run a small or large manufacturing business, the FlexWeld system gives you the flexibility and accuracy you need to stay competitive.
Are you ready to improve your operations?
If you want to take your welding to the next level, contact Infinite Robotics today. We can help you solve your challenges, reach your goals, and get the most out of your business.