Industrial Welding Robots Improve Your Profitability and Productivity

Aug 31, 2023

According to Intrado GlobeNewswire, the global robotic welding market size was valued at $5.5 million in 2018, and is projected to reach $10.5 million by 2026, growing at a CAGR of 8.7% from 2019 to 2026. These numbers are no accident, as the market implements Industry 4.0, manufacturers will continue to seek ways to improve operations through automation. With no shortage of robotic welding equipment, the heavy investment by various industries in robotics technology has encouraged the further development of automated welding.

Accord­ing to Intra­do Globe­Newswire, the glob­al robot­ic weld­ing mar­ket size was val­ued at $5.5 mil­lion in 2018 and is pro­ject­ed to reach $10.5 mil­lion by 2026, grow­ing at a CAGR of 8.7% from 2019 to 2026. These num­bers are no acci­dent, as the mar­ket imple­ments Indus­try 4.0, man­u­fac­tur­ers will con­tin­ue to seek ways to improve oper­a­tions through automa­tion. With no short­age of robot­ic weld­ing equip­ment, the heavy invest­ment by var­i­ous indus­tries in robot­ics tech­nol­o­gy has encour­aged the fur­ther devel­op­ment of auto­mat­ed weld­ing.

Automa­tion is a long-term invest­ment, with cost sav­ings not seen in one lump sum, rather incre­men­tal­ly over the life­time of the robot. Improv­ing prof­itabil­i­ty starts with being able to cal­cu­late the return on invest­ment (ROI) of the auto­mat­ed sys­tem. Robots​.com has an ROI cal­cu­la­tor for busi­ness­es to work out their pay­back peri­od, the peri­od it will take for the invest­ment to break even. These cal­cu­la­tions estab­lish the expec­ta­tions of the prof­itabil­i­ty of a sys­tem with most com­pa­nies plan­ning to reach a return on invest­ment over a 2 – 3 year period. 

Once a return on invest­ment is achieved the sys­tem is now direct­ly improv­ing the prof­itabil­i­ty of a busi­ness through its effi­cien­cy, reli­a­bil­i­ty, and qual­i­ty con­trol. Indus­tri­al weld­ing robots are faster when com­pared to man­u­al process­es. Typ­i­cal­ly the indus­try cal­cu­lates that a robot­ic welder is equiv­a­lent to 3.5 man­u­al welders in terms of pro­duc­tiv­i­ty. This equates to an 85% increase in pro­duc­tiv­i­ty for a busi­ness when using an auto­mat­ed system. 

This increase is fur­ther com­pound­ed when con­sid­er­ing the effect the auto­mat­ed sys­tem has on the over­all qual­i­ty of the weld too. While being faster than man­u­al coun­ter­parts, robot­ic sys­tems can also guar­an­tee the qual­i­ty of the weld every time, nev­er mak­ing errors and always result­ing in a smooth, clean result. In a man­u­al work­shop, an oper­a­tor may make many errors, often opt­ing to hide the mis­take by going over it again with the torch. While this alone is incred­i­bly inef­fi­cient in terms of time, it’s also waste­ful of resources and can hide a pos­si­bly flawed weld. Because an auto­mat­ed weld sys­tem will pro­duce the cor­rect result on the first try, robot­ic sys­tems will save man­u­fac­tur­ers mon­ey in resources and in qual­i­ty con­trol errors – direct­ly affect­ing the prof­itabil­i­ty of the bot­tom line. 

Anoth­er impor­tant aspect affect­ing the prof­itabil­i­ty and pro­duc­tiv­i­ty of weld­ing is the time spent on weld­ing itself. Stud­ies have shown that for man­u­al welders, only 30 to 40 per­cent of the time is spent weld­ing. Oth­er tasks involved in the weld­ing process such as han­dling, clean­ing, heat­ing, and cool­ing take up almost 60 to 70 per­cent of the operator’s time. Robot­ic weld­ing sys­tems, on the oth­er hand, require min­i­mal down­time for things like clean­ing and heat­ing or cool­ing. This allows the weld­ing robot to spend most of its time in the pro­duc­tion phase. 

The adop­tion of weld­ing robots ensures increased pro­duc­tiv­i­ty on weld­ing lines. Auto­mat­ed sys­tems also reduce inten­sive labor injuries, improve order ful­fill­ment speed & accu­ra­cy, and increased uptime with reduced costs. This tech­nol­o­gy also enhances the effi­cient use of work­ing space and improves the sup­ply chain per­for­mance in end-user indus­tries, over­all improv­ing the prof­itabil­i­ty and pro­duc­tiv­i­ty of the busi­ness­es smart enough to imple­ment the technology. 

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