Operational challenges
The traditional production model for these components faced challenges due to the variety of the product range:
- Variety management: requirement to process different pipe sizes, shapes, and flange types.
- Setup times: conventional mechanical systems require significant downtime for each product to change.
- Process efficiency: difficulty in balancing cutting, punching, threading, and welding operations in a single continuous flow.
The strategic solution
The infrastructure is based on an architecture of four anthropomorphic robots working in synergy, integrating all technological phases:
- Integrated process: the 6-meter tube is automatically cut to size, punched, and threaded.
- Robotic welding: integration of pressed flanges via spot welding managed by robots for consistent precision.
- Computer vision: advanced vision systems for part recognition and positioning, ensuring maximum handling flexibility.
- Batch-one production: management software allows for instantaneous format changes, making the production of small batches efficient.
Results and value generated
The implementation of this smart manufacturing solution achieved new standards:
- Cycle optimization: a perfectly balanced workload among robots to maximize output and reduce idle time.
- Total flexibility: ability to respond in real-time to market demands for small and diversified batches.
- Quality and repeatability: millimetric precision in CNC processing and welding, leading to a drastic reduction in waste.
- Modularity: the system is designed to adapt quickly to new product variants without structural modifications.
