Grinding Out Results: How A Steel Fabricator Boosted Output & Upskilled Workers
Lawrence Brothers boosted tray production and consistency while reducing injuries by automating grinding with GrayMatter Robotics.
Challenges
- Manually challenging and injury-prone job
- High turnover rates and limited local workforce
- Routine rework required that slowed down production
Results
Production increased by 38%
Consistent product results
Necessary rework decreased by 95%
Upskilled employees
Material cost savings of $2,000 per week
Story
In Bluefield, Virginia, Lawrence Brothers Inc. has been operating as a steel fabricator of metal material handling trays for more than 50 years. Each day, the shop produces 1,000 trays requiring a tiresome and injury-prone grinding process that has led to high turnover in a region that already suffers from limited workforce.
With the goal of fostering team longevity and embracing a healthier work environment, Lawrence Brothers sought out GrayMatter Robotics, a FANUC Authorized System Integrator, to automate this challenging task.
Using their proprietary AI technology and a FANUC M-710 industrial robot, GrayMatter Robotics implemented a solution that scans various kinds of metal trays and grinds them accordingly, with the flexibility to change parts with every cycle.
From its first week in operation, the robotic grinding solution was reaching its target rates while creating consistent results that dropped necessary rework from eight to 10 trays per day to eight to 10 trays per month or more—with no rework ever attributed to grinding. With the new system in place, Lawrence Brothers has also realized material cost savings of $2,000 per week on grinding discs.
While production has increased production, the most notable change has been in how employees are supported—automation has enabled easier training and skill development, allowing team members to take on more meaningful roles and experience significantly less physical strain.
“Not only did it lessen their physical workload but it gave them a little more responsibility. We upskilled them into another position which in return benefited us but also benefited them. When they get off, they can go home and play with their kids—they're not dead tired.” said Heath Harris, Production Manager, Lawrence Brothers.
In bringing in GrayMatter Robotics to help us develop robotic components that will replace some of the hard manual labor, I feel that we're able to provide longevity for our guys. We're able to provide a life that is focused on not ‘living to work’ but more ‘working to live.'
Melanie Protti-Lawrence President – Lawrence Brothers Inc.FANUC Products Used
M-710iC/70
The FANUC M‑710iC/70 is a compact 6 axis robot suitable for various applications and combines a 70 kg payload with extremely high axis speeds.
- Max Payload:
- 70 kg
- Reach:
- 2050 mm
Meet GrayMatter Robotics, FANUC Authorized System Integrator
At GrayMatter Robotics, we’re not just changing the game in manufacturing; we’re improving the quality of lives. Our mission is to empower manufacturers with smart robotic cells that boost production capacity and alleviate the physical strain of repetitive and ergonomically challenging tasks. In an industry where many workers endure the daily grind of manual labor, we provide a solution that not only lifts the burden off their shoulders but also opens up new avenues for career advancement. By transitioning from demanding roles to becoming skilled robot operators, employees can upskill, gain advanced competencies, or even step into management positions. This transformation allows them to thrive in their careers and enjoy a better quality of life.
About Lawrence Brothers Inc.
Lawrence Brothers Inc. (LBI) was incorporated in Virginia in 1975 as a manufacturing company specializing in heavy metal fabrication and custom metal applications for various industries, including underground mining, energy and electrical, automotive, material handling, airline and the general metal industrial goods industry. Founded in 1974 by brothers Jim and Dale Lawrence in a three-car garage in Springville, Virginia, the operation originally fabricated mine battery trays for Exide Battery, and now holds 45 percent of the market share of mine battery trays, which are utilized in battery-powered equipment produced by manufacturers. Based in Bluefield, Virginia, LBI has grown to more than 100 employees and 80,000 square feet of manufacturing space.
