Hutchison Inc. Boosts Production with Launch of Robotic Welding
Hutchison Inc. increased gate production by 37% and improved weld quality by automating a challenging welding line with FANUC robots.
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Challenges
Workforce shortage that made meeting demand difficult
Difficult production process requiring welding a light gauge round steel
Required high-quality and low-defect results that were at least as efficient as skilled employees
Results
Fully automated process ensures more consistent welds, higher quality finished products and fewer defects
Increased employee satisfaction and less need for overtime
Increased steel gate production by at least 37% per hour
Story
Facing a workforce shortage and struggling to meet demand, livestock and equine product manufacturer Hutchison Inc. turned to automation to address a particularly difficult welding production line for their steel gate products.
To ensure that they had access to on-site support before, during and after the delivery process, first-time robotics user Hutchison Inc. relied on Colewell Automation in central Iowa to develop a solution that could match the high-quality work of their skilled welders.
To minimize lead time and get the system up and running as quickly as possible, Colewell Automation used simulation software to design a dual-sided cell with two FANUC robots and Lincoln welding equipment. With an STT option in the center that alternates between fixtures on either side, the robots are able to work on one side while a two-person welding team unloads and reloads the other side of the system. By using simulation software to design the cell, both the build time and installation process was shortened, resulting in as little downtime as possible.
With the automated system in place, Hutchison Inc. has increased gate production from 8-10 per hour to 11-13 per hour, an hourly increase of at least 37 percent. In addition to this, finished products feature more consistent welds and higher quality overall, with far fewer defects. According to Breanna Anderson, robotic welding team leader, the team is enjoying not only the process, but “using problem solving skills and welding skills to get things moving and grooving again.”
We wanted to weld a hard to weld product at the same pace, and quality, that our skilled welders do upfront matching matching the daily output that they have with, quality and low defects.
John Bavester Operations Manager – Hutchison Inc.FANUC Products Used
ARC Mate 120iD
A versatile arc-welding robot that boosts productivity and profitability with low operating costs and easy installation.
- Max Payload:
- 25 kg
- Reach:
- 1831 mm
Colewell Automation LLC
At Colewell Automation, people come first. And when we all work together, we can do anything. As a FANUC and Lincoln Authorized Robotic/Systems Integrator, the Colewell team brings passion, curiosity, and determination to provide turn-key and custom automation systems, robot programming, production improvement, and fast, personal customer service to manufacturers across the Midwest and beyond.
Hutchison Inc. (HW Brand)
Hutchison Inc has been in business for over 70 years. Once a small moving business it has grown to become one of the top manufacturers and distributors of livestock and equine equipment, fencing and wire products, baling supplies, and lumber and building materials. We take pride is serving farm and ranch stores, rural farm cooperatives, lumberyards, implement stores, and hardware dealers throughout rural America. Over the years the company has expanded, creating a total of five divisions: Hutchison Western; Hutchison Lumber and Building Products; HW Brand Manufacturing Company; Hutchison Transportation; and Logan Valley Manufacturing.