Operations Efficiency – Robotic Weld Optimization

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Problem

Customer experiencing excessive downtime & high maintenance costs

Weld tips replaced three times per shift regardless of condition as precaution to ensure quality compliance

Actions

Extend tool utilization without reducing uptime, performance, or welding quality 

Deployed data visualization and leveraged ML to develop replacement predictive maintenance

Automated process with IoT platform

Solution

IoT platform to automate the process

Identified optimal weld tip replacement frequency

Reduced data load on PLCs by implementing simplified architecture

Results

  • Achieved $1m in annualized savings in maintenance costs globally
  • No reduction in weld quality or machine uptime
  • Maintenance teams freed up to focus on other critical events
  • Time to completion: 4 weeks
Robotic