Automotive Supplier Cuts Costs with Robot Laser Cutting Automation
WKW North America achieved cost savings and high‑precision aluminum laser cutting using a fully automated FANUC robotic system with SPA’s NEWTON head.
Challenges
- Handle products with custom shapes, sizes and precision features
- Achieve rapid cycle times and changeovers
- Improve quality
Results
Story
WKW North America is a Tier 1 automotive supplier of aluminum anodized extrusions. They recently selected Shape Process Automation (SPA), a FANUC Authorized System Integrator, to design an automated solution to produce structural aluminum parts at their facility in Portage, Michigan. Initially, WKW requested standard islands of automation, but after the team at SPA explored cost models using their ROI automation tools, the alternate solution achieved a more cost-effective approach to producing the parts.
The fully automated laser cutting system includes multiple FANUC six-axis robots equipped with SPA’s innovative three-axis laser cutting head called NEWTON®. The robots are extremely repeatable and consistently find the right location on the part for laser processing. The NEWTON® cutting head device provides down to ±50µm accuracy as it cuts the required shape. NEWTON® works at far higher speeds and accuracy than previous robotic laser cutting systems.
The combination of traditional robotic laser-cutting technology with SPA’s NEWTON ® proprietary laser cutting head has allowed WKW North America to achieve their goals and experience significant cost savings.
We found the only way to meet our requirements for quality, precision and cycle time was the technology that Shape provided.
Prakash Patel Director, Program Management – WKW North America
This technology is very robust, dependable, and precise – and it’s easy to use. The lowest cycle time we have is 26 seconds per part. We can get over a thousand parts in an 8-hour shift. It's very exciting, honestly, pressing the start button and it’s ready to go.
Justin Bald Manufacturing Engineer – WKW North AmericaFANUC Products Used
R-2000iC/210F
The FANUC R‑2000iC/210F is a 6 axis material handling robot ideally suited to any number of heavy handling jobs on almost any application.
- Max Payload:
- 210 kg
- Reach:
- 2655 mm
M-20iB/25
The FANUC M‑20iB/25 is a compact 6 axis robot that has been designed to achieve faster cycles and increased throughput on a range of applications.
- Max Payload:
- 25 kg
- Reach:
- 1853 mm
Meet Shape Process Automation, FANUC Authorized System Integrator
Shape Process Automation is a leading automation systems provider and robot integrator. Shape designs and builds automation systems for leading manufacturers across North America and the world.
About WKW Group
Leading supplier of aluminum, steel, and plastic materials for the automotive industry. Components include trim, roof rails and extrusions, as well as design-oriented industrial applications.
