Welding plays a vital role in manufacturing, creating durable and reliable joints essential for countless products manufactured today. With the rise of advanced technology, automated welding systems are reshaping industries by delivering precision, efficiency, and productivity on an unprecedented scale. But what specific benefits does automated welding bring, and how can it redefine manufacturing workflows?

The Benefits of Automated Welding

There are many benefits to automated welding systems, which range from Gas Metal Arc Welding (GMAW) and resistance to laser welding systems.  A few of the benefits are discussed below:

Consistency: Automated welding systems deliver uniform welds and maintain consistent quality throughout production. By leveraging automated machinery and advanced control technologies, manufacturers can reduce defects and achieve reliable results across all workflows.

However, automated processes that provide consistent, high-quality results also require consistent and high-quality inputs.  Parts being joined through welding must be relatively clean and meet the dimensional tolerances of the automated machinery.

Higher Efficiency: Unlike human welders, automation can operate continuously without breaks, fatigue, or declines in output. This capability dramatically increases production throughput, helping manufacturers meet demanding schedules and expand their operations.

It is important to keep in mind that to maintain efficiency, regular maintenance of the machinery is a must.  Not every company includes maintenance downtime in their Overall Equipment Effectiveness (OEE) calculations; however, it is important to do so to understand the true efficiency of the machinery.

Cost Efficiency Over Time: While the initial cost of implementing automated welding can be substantial, long-term savings often justify the investment. Reductions in material waste, fewer product reworks, and lower labor costs contribute to cost-savings over time.

Improved Workplace Safety: Welding involves hazards such as extreme heat, intense light, and toxic fumes. Automated systems remove human workers from direct exposure to these risks, which can create a safer and more sustainable work environment.

Even in automated welding systems, however, proper safety measures must be followed.

Key Steps for Successful Integration

Prior to automating your factory’s welding processes, it is important to follow the steps below, whether the factory already has automated welding systems, or is looking at investing in them for the first time.

1. Identify Automation Opportunities: Evaluate which welding tasks can benefit most from automation, particularly repetitive, high-volume jobs or those with stringent quality demands.  Not all welding processes will be suited for automation.

2. Select the Right Technology: Once a process is identified as being suitable for automation, the next step is to determine an automated welding system/process that is most suitable for that process and potential future needs of the company.   The decision as to whether a fixed welding cell or something more flexible, such as robotic welding, will need to be made depending on the current and future needs of the company and specific intricacies of the welding process being automated. 
Facteon has worked with multiple welding technologies.

3. Analyze Costs and Benefits: Conduct a detailed cost-benefit analysis, accounting for potential savings in labor and materials, as well as improvements in quality and safety. At Facteon, we have typically seen payback periods ranging from 10 to 24 months. 

4. Prepare Your Workforce: The factory team will need to be able to operate and maintain the equipment effectively. If the necessary skills are not already an internal resource, consider using a third-party service provider.

Challenges and Key Considerations

While automated welding can provide significant benefits, there are also some challenges to be overcome. The initial investment can deter some smaller manufacturers, and integrating these systems requires technical expertise that may not be readily available in your area. Variations in materials and product fit-up may demand ongoing adjustments, which requires someone who is comfortable working with advanced automated production machinery, adding to both complexity and cost.

At Facteon, we advance automation. If you are considering automating welding processes in your manufacturing operations, our team of engineers are more than happy to discuss with you the pros and cons related to your specific circumstances. 

Facteon is a full-service advanced industrial automation company capable of designing, fabricating and installing bespoke manufacturing lines or individual cells. Furthermore, our team is capable of refurbishing or upgrading your automation equipment as well.