A Hungarian automotive supplier approached our team: manual welding had become the bottleneck, and even two shifts could not keep up with the growing volume. The goal was clear — shorter cycle time, repeatable quality and a documented process.
The starting point
The workpiece was a welded chassis component with 14 seams, accessible from two sides. The manual process had a cycle time of 11.2 minutes with considerable variation. Weld quality depended on the operator, with recurring audit findings.
The solution
We designed a two-station Neuraweld cell: while the robot welds at one station, the operator unloads and loads at the other. TAST seam tracking on the Kemppi AX MIG power source compensates for pre-fabrication tolerances, and WeldEye logs every weld.
In the simulation phase we estimated the cycle time to within ±3% — the test piece confirmed it on the trial day. Six weeks after installation and the SAT test, the cell was running in series production.
The result
- Cycle time: 11.2 min → 6.9 min (−38%)
- The capacity of the former two shifts in a single shift
- Auditable weld logging with WeldEye
- Payback: 22 months
Facing a similar challenge? Book a 30-minute consultation — the process assessment is free.