Having strong leaders and employees who are not afraid of welding automation is essential to the successful implementation of the robotic welding cell. Getty Images
Your workshop calculated the data and realized that the only way to do more work now and stay competitive with innovation is to strategically automate the welding or manufacturing process. However, this critical update may not be as easy as it seems.
When I visit small, medium, and large clients who want automation to help them compare systems and choose the one that suits their needs, I highlight a factor that is often overlooked when deciding when to automate—the human factor. For a company to truly benefit from the efficiency gains that the transition to automated operations brings, teams must fully understand their role in the process.
Those who worry that automation will make their work obsolete may hesitate when making automation decisions. The truth, however, is that automation requires welding skills indispensable for skilled workers. Automation is also creating new, more sustainable jobs, providing growth opportunities for many skilled welders who are ready to advance in their profession.
Successful integration of automated processes requires a change in our understanding of automation. For example, robots are not just new tools, they are new ways of working. For automation to have valuable benefits, the entire shop floor must adapt to the changes that come with adding robots to existing workflows.
Before jumping into automation, here are the steps you can take to find the right people for the job in the future and prepare your team to manage and adapt to changes in the process.
If you are considering automation, you must also consider how this shift in work styles will affect existing shop floor workers. The most important thing that prudent employees should pay attention to is that automated welding processes still require human presence. In fact, the best option for successful automated welding is when the driver can own the process, have a fine understanding of welding, and have the confidence and ability to work with advanced digital technology.
If your vision for an automated process involves faster production and lower costs from the outset, you need to first fully understand all the cost drivers. Most customers only focus on speed rather than weld quality and safety, and we’ve found that this is often a bigger factor in hidden costs that can affect your ROI calculations.
When it comes to weld quality, you need to make sure your process produces the correct weld size and desired penetration, as well as the correct shape. Also, there should be no welding spatter, undercuts, deformations and burns.
Experienced welders are good weld cell operators because they know what a good weld is and can fix quality problems when they arise. The robot will only weld the welds it has been programmed to do.
From a safety point of view, you need to consider smoke extraction. Also check that your safety procedures are up to date to prevent injury from overheating and arc flash. Ergonomic risks associated with material handling and other industrial activities must also be considered.
Automation often ensures consistent weld quality and eliminates certain safety concerns because workers are not involved at all in the process. By focusing on welding quality and safety, you can be sure that production will speed up.
As technological innovation continues to improve our processes, it is important to adapt how we work to remain globally competitive. Also, it’s important to update how you define talent in your workforce.
Look around the workshop. Have you seen someone with a new phone or heard someone talking about video games with friends? Anyone excited about the new navigation system or the truck’s specs? Even if the people involved in these conversations have never used a robot, they may be the best option for working with an automated welding system.
To find the strongest people in your team who can become your internal automation experts, look for great people with the following characteristics, skills and qualities:
Learn the mechanics of welding. Most of the company’s problems or concerns about product quality usually stem from welding problems. Having a professional welder on site helps speed up the process.
Open to learning how to use new technologies. An operational potential owner with a willingness to learn is a sign of further flexibility as innovation continues.
Experienced PC user. Existing computer skills are a solid foundation for training and operating robots.
Adapt to new processes and ways of working. Have you noticed that people willingly implement new processes both at work and outside of it? This quality contributes to the success of the automated welding module operator.
The desire and excitement to own a piece of equipment. Robots are an exciting new tool with many features to learn and master. To some, science seems natural, but for those closely associated with robotic cells, it’s more important to be flexible, adaptable, and teachable.
Before setting up a welding cell on the manufacturer’s shop floor, management needs to involve the manufacturing team in the project and identify leaders who can successfully deliver it.
A strong leader who can drive change. Those in charge of operations will benefit from rapid learning and the ability to identify potential long-term problems and solutions.
Support other workers throughout the transition. Part of the leader’s role is to support their colleagues in the transition to automation.
Feel free to look for the most difficult tasks and take on challenges related to new technologies. Owners of automated welding processes need to be confident enough to make the necessary trial and error as your company tackles the challenges of implementing any new technology.
If you don’t have your team members willing to become “facilitators” of such automation projects, you might consider hiring someone or delaying the transition to automation by training your existing staff in the skills and plans needed to make the project a success.
While the transition to automation is a huge opportunity for welders looking to improve their skills, many of the welders present are not ready to operate welding robots, either because they are not trained in this new process or because they have not received additional technical school training. .
We usually see engineers, supervisors or middle managers in charge of the process, but the involvement of highly skilled welders is important as they are critical to successfully navigating and adapting to changing processes. Unfortunately, welders have neither the time nor the financial incentive to take on extra work or additional training outside of their normal duties.
The transition to automation can be a slow process that requires some early adopters (those who have the opportunity to be trained to be the driving force behind the project) to take the lead. They also help keep the drive for automation alive with their co-workers, which may encourage others to take an interest in automation as a career option.
Deciding which project you want to start is also key to a smooth warm-up for your team. Many clients say they want to make smaller, simpler jobs their first automation project to flatten the learning curve. When your team starts to automate, consider subassemblies as the first goal of automation, not more complex assemblies.
In addition, training provided by the American Welding Society and specific robotics OEMs is integral to a successful automation implementation. In-depth training from OEMs is essential for leaders in the implementation of automated welding modules. In this context, project drivers can navigate and troubleshoot device-specific issues that may prevent a smooth transition. The driver can then share the knowledge gained during the training with the entire team so that everyone has a deeper understanding of robotics.
An excellent reseller partner with experience in configuring a variety of automation devices can provide critical support throughout the transition process. Distributors with strong service teams can support you through the onboarding process and provide maintenance throughout the automated life cycle.
Bill Farmer is National Sales Manager for Airgas, Air Liquide Co., Advanced Manufacturing Group, 259 N. Radnor-Chester Road, Radnor, PA 19087, 855-625-5285, airgas.com.
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