The welding market is becoming highly competitive, and the shortage of professional, skilled welders can make it challenging for companies to persevere. Collaborative robots (cobots) can help businesses keep up with high demand while taking repetitive and strenuous workloads off their workforces. These robots help scale welding operations by improving consistency, collaborative work and safety.

The Role of Industrial Robots in Welding

Industrial robots boost efficiency, precision and safety in the welding industry. They’re beneficial for automating large-scale, repetitive jobs. While Industrial robots remain popular for such tasks, they aren’t as effective at more complex ones.

However, cobots can handle more intricate jobs alongside human welders. They assist with routine tasks like quality control and assembly, allowing welders to prioritize more complex work.

What Are Cobots?

Cobots are robots designed to assist and work alongside human operators. Unlike traditional robots, they aren’t limited to safety zones but still ensure a safe workspace. Safety features like sensors allow cobots to detect humans in their vicinity and adjust accordingly, allowing businesses to harness the strengths of robotics and human workers simultaneously.

While traditional robots are ideal for automating heavy-duty, repetitive welding jobs, cobots are more flexible and versatile, making them better for complex operations. They’re designed to be easy to program, integrate and reprogram so humans can interact with them more effectively. Workers can use them for various applications, boosting adaptability and productivity.

Cobots are easier and more cost-effective to integrate into an existing workspace than traditional robots. That’s because of their smaller size, built-in safety features, and collaborative design.

Contact a Meritus Gas team expert for more information on cobots.

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The Benefits of Cobots in Reducing the Expenses of Automation in Manufacturing

Automating your manufacturing line using welding cobots can save your company money, boost productivity and improve safety. They can transform how your welding operations function through the following benefits:

1. Addresses Welder Shortages

Fewer young people are pursuing careers in welding, and the United States is expecting a welder shortage of around 330,000 by 2028.

Many companies are addressing the welder shortage through automation. They’re using industrial robots to take on the bulk of simple, repetitive tasks and cobots to aid welders with more complex and routine jobs. These applications allow human welders to prioritize more creative and intricate work.

Companies can maintain higher production levels by automating specific welding tasks despite having fewer welders. Cobots also help small-to-midsize enterprises (SMEs) account for these shortages even without the volume of work required to implement industrial robots.

2. Boosts Cost-Effectiveness

The most significant expenses involved in welding include reject and rework costs, labor costs, non-value-added tasks, and post-weld operations. Automation helps reduce all of these in a large section of the industry.

Cobots reduce labor costs by taking over routine and time-consuming jobs and helping welders complete more complex tasks efficiently. They also create cleaner and more precise welds, reducing the number of defects and errors. Fewer reworks or scraps result in lower overall production costs.

Another area where cobots save money is their cost compared to traditional automation solutions. Their initial expenses are typically lower than those of industrial robots. They’re also more affordable to maintain and require less infrastructure to install and integrate into a workspace.

3. Improves Quality and Consistency

Automation in manufacturing is more precise and consistent. For example, cobots consistently produce uniform welds, reducing human error and increasing weld quality. Studies show that when staff cooperate with a cobot, task complexity is decreased, which reduces human workload and improves output quality.

Quality standards are high, and cobots ensure the same level of quality is achieved with every weld. They maintain these standards throughout production without variation, even in areas human welders struggle to reach.

4. Simplifies Installation, Programming and Maintenance

Automation solutions like industrial robots require complex and expensive installation and maintenance. However, a cobot’s user-friendly interface makes it easy for operators with little to no technical knowledge to set up and maintain them.

Programming cobots is straightforward. Common methods include lead-through programming, graphical tablet interfaces using interlocking drag-and-drop blocks and even standard programming languages.

5. Increases Safety and Collaboration

Automation makes your manufacturing process safer for your workers. Industrial robots require safety zones, removing humans from hazardous environments. Cobots improve safety while working alongside human welders and operators. They have reactive sensors that detect workers and objects and prevent accidents by adjusting their movements accordingly.

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6. Enhances Flexibility and Adaptability

Automation solutions make your manufacturing line more flexible. While traditional welding robots handle high-volume repetitive tasks, they require extensive programming and setup. However, cobots are more adaptable because they’re designed to be easy to reprogram. As production needs change or require customization, cobots can be easily adjusted to perform different welding tasks or added to existing fleets.

7. Enhances Productivity

Fatigue is a significant factor affecting human productivity. However, cobots can consistently and uninterruptedly provide high-quality welds. Incorporating cobots into the workload positively impacts the organization’s overall performance. Using them for routine, time-consuming jobs allows human welders to prioritize skilled and intricate tasks, reducing lead times and boosting productivity.

Companies can leverage the problem-solving and decision-making skills of human welders and the endurance and precision of cobots.

8. Speeds up Return on Investment (ROI)

While automation solutions depend on your company’s needs and goals, they typically reduce operating costs and increase output, quickly covering the initial investment.

Welding cobots can yield exceptionally high ROIs in a short amount of time. They increase productivity and quality and reduce labor, maintenance, and waste costs. Cobots are even more effective in SMEs with low-volume production.

Key Considerations for Implementing Collaborative Welding Robots

Welding cobots can improve productivity, competitive advantage and efficiency in your manufacturing process. However, it’s essential to consider these key factors when implementing them into your workspace:

Cobot integration: Cobots are versatile, compact and easy to integrate into existing workflows.
Impact of welding costs: Cobots may have a high initial investment but reduce costs and increase profits in the long run.
Welding equipment: Various attachments and tools are available to suit welding cobots’ tasks. Check that all supplies and gases used are compatible.
Scaling operations: Welding cobots are easy to integrate and compact, so they can be easily added to meet your business’s production demands.
Implementing maintenance: Cobots require regular maintenance, such as daily visual checks, software updates, and cleaning optics and sensors. Working with a qualified technician is vital if the cobot shows signs of malfunctioning.

Contact a Meritus Gas team expert for information on cobot repairs and maintenance.

Increase Welding Output With Cobot Solutions From Meritus Gas Partners

At Meritus Gas Partners, we’re experts in assisting companies with streamlining welding operations and cutting costs through our innovative cobot solutions. Our experts help companies cut gas costs by tailoring the right package for their needs and offering competitive prices.

Additionally, we partner with robotics companies to provide you with the most advanced technology. MOD-WELD cobots from APT Manufacturing Solutions have a user-friendly interface that enables workers to perform complex or tedious tasks consistently.

Find a partner near you or speak to one of our experts for more information on integrating cobots into your welding operations.

Collaborative robots (cobots) help metal fabrication processes ranging from measurement and layout to cutting and welding. Metal fabrication businesses can program them to connect with existing computer systems and robots to streamline automation. These collaborative robots are also equipped with features like smart sensors to increase accuracy and safety.

Read on for more information on cobots in manufacturing and how cobots can help metal fabrication businesses boost productivity and outputs. Learn the strategies involved in each step of integration, from preparation to maintenance.

Characteristics of Cobots

Cobots are programmed to execute complex projects using a robotic arm, supporting tools and a programming interface. They are fundamentally different from traditional robots.

Traditional robots work separately from human activities, take up larger spaces and require sufficient downtime to reprogram. Cobots are programmed to safely share a workplace with humans, making workers’ duties less stressful. They’re also easier to program for new functions and are compact, allowing for improved space practicality.

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Advantages of Cobots for Metal Fabrication

Cobots can assist with many tasks involved in metal fabrication, from cutting and forming to extrusion and welding. They offer several benefits for metal fabrication companies, such as:

Boosting productivity: Cobots can perform repetitive tasks with precision, often more quickly than human workers. Manufacturers report productivity gains of 50%-300% when using cobots. Employees can focus on more urgent and complex jobs, and companies can increase profits during busy seasons by taking on more work and clients.
Managing labor shortages: When qualified welders aren’t available, cobots can help businesses pick up the slack and lessen the load on an under-staffed team.
Reducing costs: While cobots require a significant upfront investment, they’re more cost-effective in the long run. They allow your human workers to focus on more intricate tasks while handling mundane ones. That means faster processes, allowing companies to do more work and increase profits.
Increasing consistency in precision: Cobots can be programmed to complete precision tasks consistently, while human welders can cause irregularities. This benefit results in more consistently accurate welds with repetitive tasks.
Improving safety: Cobots come with sensors that can detect people or objects in their vicinity. This feature allows them to reduce their movement speed or shut down to prevent collisions, resulting in a safer work environment.

Strategies for Integrating Cobots Into the Metal Fabrication Process

Integrating cobots into the metal fabrication process can boost productivity and morale and save labor costs. They are designed to be simple for employees, requiring minimal additional training and skills. Here are the typical strategies that companies implement in each step of working with cobots:

Cobot Integration Preparation

To prepare, metal fabrication companies must identify where a cobot can be used and determine the appropriate end-of-arm tooling required to master the necessary tasks. They must also ensure their selected size can function safely among human workers without other physical obstructions.  

Businesses can base the decision to integrate cobots into the workforce on risk assessments. Specific tasks may pose occupational safety risks or cause workers to waste effort on repetitive tasks. Cobots can be programmed to perform specific functions that may reduce hazards for workers or boost efficiency by allowing employees to focus on more complex tasks.

An often overlooked step in preparation is informing staff of the benefits of cobots and addressing any anxiety or concerns they may have about their new co-worker. It’s essential that the team is onboard and understands the cobot is there to assist and improve productivity.

Once the company has allocated the proper space, task and safety requirements, they can successfully integrate the cobot into the workplace.

Cobot Programming and Training

Once the cobot is installed, it must be programmed, and staff will receive training.

Detail the physical steps: Employees physically take the cobot arm through the coordinates of different stages of the required metal fabrication process.
Outline the input and output: Workers enter each task’s start and end points into the software. 
Create a task library: The staff repeatedly moves the cobot arm through each stage for different tasks. This step creates a library of programs workers can use for future tasks that could benefit from cobot assistance. 

Unlike traditional robots, cobots aren’t solely dependent on the skills of highly trained programmers. Companies can train them to perform specific functions by training staff to work with specialized programs. The training isn’t extensive, as the user-friendly software makes it easy for workers to ensure precision, safety and accuracy with required tasks. Once programmed, staff only need to select the correct task parameters like feed, speed and values. 

Most suppliers offer training to get staff comfortable with new equipment, ensuring a smooth transition to utilizing cobots in welding tasks.

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Post-Integration Maintenance and Support

Conducting regular maintenance and support is crucial to ensure cobot integration runs smoothly without causing significant downtime. Here are the general steps involved in cobot maintenance:        

Conduct daily visual checks: Staff should have a transparent process for identifying potential issues, such as misconfigured cables and bolts. Reporting and fixing these issues early on can prevent extended downtime. 
Clean sensors regularly: Cobots rely on sensors and optics to perform tasks accurately and easily move items. Workers should ensure the sensors are free from dirt and dust. 
Perform software updates: Regular software updates enhance the cobot’s safety features and new operational features, which can make troubleshooting easier in the future. 
Work with qualified technicians: When the cobot needs repairs, it’s crucial to work with knowledgeable professionals when the cobot needs repairs to ensure safety and prevent further damage. 

The Future of Cobots    

Cobot technology is set to coexist in many industries to help employees work more productively and accurately. It will also bridge the gap in fields with shortages. For example, the American Welding Society highlights that the United States has a shortage of around 400,000 welders, which has a drastic ripple effect on many industries. Cobots can play a crucial role in reducing labor stress in this field and ensuring companies reduce bottlenecks and meet deadlines. 

Cobots can help metal fabrication businesses meet deadlines, boost accuracy and reduce employee stress while increasing orders.

Upgrade Your Output With Cobots From Meritus Gas Partners

Are you looking for cobots to streamline processes in your metal fabrication business? At Meritus Gas Partners, our associates offer cobot solutions that can handle repetitive or complicated tasks with unmatched accuracy and speed. For example, MOD-WELD cobots from APT Manufacturing Solutions have the flexibility and precision to conduct robust welding tasks with a user-friendly interface your staff can integrate seamlessly. 

If you’re unsure where to start, speak to one of our experts today. Feel free to request a quote from us, or find a partner near you to learn more about purchasing a cobot. 

Small and midsize enterprises (SMEs) that want to stay competitive must integrate intelligent technology into their workforce. Cobots are one of the best ways to reap the benefits of artificial intelligence (AI) and technology in a way that helps employees do their jobs better and creates financial success. There are many advantages to integrating cobots into the workplace, and they have the potential to handle tasks in several industries.

What Are Cobots?

A collaborative robot (cobot) is a robot that works alongside humans or other cobots to accomplish certain tasks. Cobots are designed to offer better accessibility and mobility to human workers. They can make certain tasks easier and less stressful for employees. The main purposes of a cobot are to prevent error, increase safety and streamline and simplify procedures.

When many people picture robots in the workplace, they envision conventional industrial robots that involve large and heavy parts and perform tasks away from human workers. While these robots have their place, cobots offer unique benefits.

Applications of Cobots in Manufacturing SMEs

The International Federation of Robotics estimates that in the next decade, more than 50% of production operators will be working with robots. Here are some of the top ways to use cobots in the manufacturing sector: 

Assembly line: Cobots can be used to accurately fasten or join objects via welding, screwing, inserting or dispensing. They can fit into tight spaces and work alongside human workers.
Material handling: Shards of metal, plastic and other heavy materials pose a risk to human workers. Cobots stack, palletize and maneuver these heavy materials and safely transport them on their mobile platforms. They also succeed in other potentially hazardous tasks like electropolishing.
Testing and inspecting: Cobots can assist with quality control checks at every stage, from manufacturing to shipment. They can be programmed to perform quality control tasks like probing and gauging. Cobots also assist human workers during busy peak seasons by taking on strenuous workloads. They can help with a wide range of tasks, from welding and packaging to machine tending, reducing the stress on human employees.

What Are the Benefits of Integrating Cobots Into SMEs?

Collaborative robots are steadily gaining popularity in industries searching for flexible solutions. Companies that may not have the capital resources or workload to take on large automation systems can benefit greatly from the expertise of cobots. Here are some of the ways SMEs in particular can enjoy the advantages of employing cobots:

1. Increased Workflow

Collaborative robots can boost productivity by working with human workers to simplify specific duties. They reduce the number of repetitive, manual tasks that take time away from human workers. For example, a cobot has been shown to reduce a 12-hour sanding job to only 3.5 hours. 

A general rule for using cobots to boost productivity is the 80/20 rule, which states that cobots should perform 80% of repetitive tasks in a workspace. This process allows human workers to spend time on more complex tasks with greater focus and energy.  

2. Improved Adaptability

Cobots have a lightweight design, meaning users can quickly maneuver them across different areas of the workspace. Users can assemble and reassemble them with ease. They can also attach to a mobile platform, allowing them to move freely throughout the workspace as needed.

Cobots have an intuitive interface that lets workers quickly switch to new tasks or setups. Thanks to their adaptive programming, these machines are flexible and fully capable of human-robot collaboration and changes in workflow.

3. Enhanced Safety

Cobots are optimized for safety. Unlike traditional robots, which typically execute their processes without any external awareness, cobots can pay attention to environmental occurrences. Cobots have a range of sensors and use AI to sense nearby humans or potential hazards.

Some models, like MOD-WELD cobots, come with safety accessories like a tabletop magnet screen and pull curtains to keep employees safe during welding procedures. Contact a Meritus Gas team expert to find out more about welding cobots.

4. Increased Space-Efficiency

Many production spaces feature numerous work zones, so it’s important that any new machinery should fit into tight spaces. Cobots are compact, allowing them to perform significant tasks in very little space. Their smaller size also allows them to easily move to different floor locations, and their smart sensors prevent them from crashing into things while on the mobile platform. The installation process for cobots also doesn’t require much space, as many parts are assembled off-site.

5. Improved Cost and Time Efficiency

The global cobot market is estimated to reach $9.2 billion by 2028, growing at a compound annual growth rate of 41.5%. One of the biggest contributors to this exponential growth is the high return on investment companies experience from cobots. 

Cobots are typically easier to install than other types of traditional robots or machinery, so companies tend to see results quicker than with other options. In some cases, cobots can be programmed to handle exclusive work that would typically require SMEs to hire a specialist. Cobots allow businesses to do more in-house, which reduces external fees and the need for expensive freelance specialists. 

What Kinds of SMEs Benefit From Cobots?

Aside from manufacturing, cobots can assist companies in various industries. Some of the most common applications are within the following sectors:

Consumer goods manufacturing: This industry streamlines its manufacturing processes by leveraging cobots. It uses them for various tasks, including product packaging and assembly, while maintaining necessary hygiene standards.
Polymers and plastics: Cobots assist workers in this industry with injection and blow molding operations, as well as heavy loading and unloading.
Electronics and technology: Cobots can automate repetitive tasks like screw-driving and dispensing, allowing human workers to engage in more creative problem-solving work.
Automotive: Cobots can perform crucial tasks like gluing, injecting engine oil, greasing camshafts and streamlining the manufacturing process.
Food and beverage: This industry has many repetitive tasks, like packaging, and cobots can make these tasks less stressful. Cobots can also work well in some harsh environments, like refrigerated zones in warehouses. 

Why SMEs Can’t Afford to Wait for Automation

With the lack of talent and unsustainable staff turnover many companies are facing, SMEs can’t afford to hesitate when it comes to implementing operational solutions. Cobots offer a level of automation that is irreplaceable to high-mix, low-volume SMEs.

Businesses face many challenges, including supply-chain challenges, tight profit margins and decreased productivity. Cobots can help with a range of tedious tasks, allowing more room for human creativity and skill and allowing companies to progress with minimal effort.

Automate Your SME With Cobots From Meritus Gas Partners

Cobots can boost productivity and make processes more efficient, all while providing a swift and impressive return on investment. At Meritus Gas Partners, we have suppliers with several cobot solutions suitable for achieving varied tasks.

Our experts have the knowledge to find exactly what your business needs, and we can even help you save money by finding you the right combination of products. If you’re interested in getting started with cobots, don’t hesitate to request a quote from us or find a partner near you to start your journey toward cutting-edge technology and manufacturing solutions.

Collaborative robots, or cobots, are becoming essential additions to production lines, including metal fabrication processes in manufacturing. However, preparing your team to welcome new equipment to do their jobs is challenging — especially when the new equipment can complete many of their everyday job tasks with ease.

Building understanding and training your employees are the best ways to highlight the advantages of cobots and automation. Learn more about cobots and how to properly integrate them into your workplace below.

Understanding Cobotics and Automation

Cobots are a type of automated robot designed to work safely alongside human workers. They’re made to supplement rather than replace human employees. Artificial intelligence, robot process automation and machine learning are the building blocks that make these machines effective and easy to operate.

The Role of Robots in the Production Line

Cobots have many applications in various industries. Their primary role is helping human workers automate repetitive and time-consuming tasks while reducing risk and maintaining consistency. Cobots prove especially useful in areas where robot arms placed behind barriers prove inadequate.

Here are a few examples:

Part joining and fastening tasks: Cobots are useful for precision welding, screwing and inserting.
Inspection and testing tasks: Cobots facilitate quality control checks such as probing, part identification and progress tracking.
Material handling tasks: Cobots can safely interact with and transport hazardous materials.

Advantages of Cobots in Manufacturing

Cobots stand out for their ability to work side-by-side with human workers. They can quickly halt operations to prevent accidents by utilizing advanced sensors to detect when a person is too close. This capability allows for a smooth collaboration of robotic efficiency and human expertise.

These are a few key benefits of using cobots in manufacturing:

Cost-effectiveness: Cobots decrease costs and time associated with production by increasing productivity and reducing errors, making them an incredible return on investment.
Boost productivity: Cobots consistently increase output, and one worker can oversee many cobots at once. Their ability to automate dangerous and repetitive tasks allows human workers to focus their attention on other key jobs.
Improve safety: Cobots use advanced programming to prevent colliding with humans. They can also handle the hazardous tasks that typically put human workers in danger.
Tackle labor shortages: Cobots are an effective and long-term solution to the lack of skilled welders. They can also operate non-stop alongside human workers during peak season. 
Deliver quality consistently: Cobots significantly reduce the need for reworks or recalls on the production line. For example, in metal fabricating, they can produce precise welds.
Offer adaptability: Cobots are flexible due to their ease of use. Quick programming allows them to adjust seamlessly to new tasks. 

Tips to Prepare Your Team for Cobots

Introducing a cobot into your manufacturing operation is a relatively simple process, but preparing your workforce for the change can take time and effort. You must highlight the machine’s benefits and train your team to operate and maintain it effectively. Here are some tips to help you ease the process:

1. Involve Workers From the Start

Be transparent with your employees about your plans to automate sections of your production line. Get your workers’ input on where they think redundancies and bottlenecks exist. Be sure to highlight the benefits of cobots and how they can provide many productivity and safety benefits on the line.

Involve your workers in the cobot maintenance process and show them their role in the automation procedure. Reassure them that the cobot isn’t replacing them but rather helping to create a safer and more efficient workplace. Investing in cobots shows your employees that you value their efforts and are serious about improving their work environment.

2. Humanize Your Cobots

Another way to improve your team’s acceptance of your cobot is to name it. Humans commonly name inanimate objects like boats, cars and computers, so why not a robot?

Naming your cobot gives it a personality, a concept called “anthropomorphism.” It improves the chances of your workers caring for it, especially when they decide on the name. Ultimately, a cobot with a name becomes less of an appliance or tool and more of a part of the team. It’s easier for your workers to accept its presence when they humanize it.

3. Prioritize Team Training and Skill Development

While these machines are designed for safety and efficiency, the workers overseeing them still need the appropriate knowledge to ensure cobot safety. Provide your workers with sufficient cobot training on how to work effectively with cobots. This coaching will teach them how to troubleshoot common errors, operate the cobot at a basic level, and program it for different tasks, such as welding.

Here are some of the key cobot skills your employees should have:

Know how cobots work: Your workers need to know how to safely maintain and handle the cobots, including the risks of working with them. This system doesn’t completely remove the risks involved in processes like welding, but a cobot is a valuable solution for protecting your employees and getting the work done.
Understand cobot programming: Production workers need some understanding of cobot applications and programming to operate them and adjust their settings when necessary. This knowledge is also valuable for cobot maintenance.
Learn where automation is needed: Higher-level employees need to understand how to identify areas that need automation and how to integrate cobots into those areas effectively. 
Feel comfortable with the machine: Workers need to be able to work comfortably with the cobots and understand how to use them to make their jobs more efficient and productive.
Be adaptable: Your organization and workers also need to know how to adapt to the changes cobots will make. Improve knowledge and skills so workers can handle the new responsibilities they’ll take on.

The right support and training make working with cobots smoother. Operating with the cobots may also indirectly teach your team more valuable skills, improving their productivity and efficiency. Altogether, ongoing learning should be a fundamental aspect of your workplace to keep your team sharp and help them become adaptable to changes.

Streamline Your Welding Processes With Meritus Gas Partners

Understanding cobots and the benefits they offer makes cobot integration much easier in your workplace. At Meritus Gas Partners, we partner with numerous suppliers of cobot solutions, giving you access to an extensive selection of the tools you need to complete welding and other processes.

We’re committed to our customers, offering the necessary support and services to help you maintain a safe and efficient production line. Contact us today or find a location near you, and take the next step toward creating a collaborative manufacturing environment with cobots.

Maximizing efficiency is at the core of every business. In manufacturing, it can mean boosting productivity, updating systems, cutting costs and taking other measures to improve throughput and maintain or increase profitability.

Considering that operational costs and the business’s bottom line are in the picture, concerns about how to improve efficiency in manufacturing remain a big part of every facility’s business strategy. To ensure team members operate in line with your efficiency standards, you must develop strategies that support your performance goals.

Introduction to Manufacturing Efficiency

Manufacturing is an extensive process that relies on your capacity to maximize operations and drive profitability in the workplace. Since your level of manufacturing efficiency is tied to profitability, it affects production costs, customer satisfaction and competitive advantage.

Importance of Efficiency in Manufacturing

How you boost efficiency in your manufacturing process will result in tangible benefits in the following areas:

Production costs: An efficient manufacturing process increases productivity, resulting in smooth operations. While that doesn’t mean there will be no hiccups, it does mean that a facility with high-performing employees and clear operational strategies will cut unnecessary costs. These strategies will facilitate channeling resources like labor, energy and materials toward value-added tasks. When everyone prioritizes spending fewer resources on low-value projects, the facility will see improvement in production costs.
Customer satisfaction: Efficiency in operations means employees can spend less time dealing with challenges or sourcing information for their next tasks. The strategies in place will provide direction at every stage and delegate duties to ensure increased production rates and improved lead times. When the manufacturing process takes less time, your facility will develop faster delivery times, which results in customer satisfaction. Fluid operations also promote quality by creating more time for quality control measures that support product quality.
Competitive advantage: Today’s digital age has simplified access to products and increased the speed at which businesses serve consumers. The more consumers prioritize better and faster services, the more pressure there is on manufacturers to leverage available resources and technological developments to stay competitive. Since competitive advantage is crucial to success, maintaining effective processes like ironing out supply chain challenges or identifying and resolving productivity gaps is key to becoming more competitive.

Current Challenges in the Manufacturing Sector

The manufacturing industry faces numerous challenges that impact overall production. While some of these challenges are out of manufacturers’ direct control, such as geopolitical crises, political reforms and climate shifts, many are tied to inefficient processes. Some of the common inefficiencies manufacturers face include:

Supply chain issues: With increased supply chain disruptions, manufacturers lacking robust supply chain strategies struggle. These issues may involve obtaining raw materials, shipping, demand planning, managing inventory and distribution.
Outdated systems: In the digital age, manufacturers using outdated systems struggle to remain effective regarding key operations like managing data and automating processes.
Skilled labor shortage: Skilled labor is crucial in keeping production lines running smoothly. Facilities that lack strategies for hiring or training workers to maintain adequate skills may struggle with productivity.
Cost management: According to a survey by the National Association of Manufacturers, one of the best ways to improve efficiency in manufacturing is managing costs, as operating costs are among the main challenges manufacturers face.

Strategies to Improve Manufacturing Efficiency

Improving efficiency in your facility requires a comprehensive review of your strategies and a step-by-step process that irons out production systems while maximizing resources. You want to identify areas that consume key resources and evaluate their output.

Here are strategies that can help you work toward improving manufacturing efficiency:

1. Automation Technologies and AI

Artificial intelligence (AI) and automation have resulted in rapid digital transformation. In manufacturing, these technologies are part of the next-level advancement you may want to embrace to keep up with the industry. As automation replaces many tasks that are often completed manually, it speeds up these processes and reduces human error, adding a layer of efficiency that is impossible without technology.

You can automate your systems through robots and by integrating AI-supported software. One of the best examples of AI and robotics in manufacturing is collaborative welding robots that operate alongside human workers to streamline industrial processes.

2. Predictive and Preventive Maintenance

Equipment is a costly and vital component in any manufacturing facility, impacting the manufacturer’s bottom line. Proper maintenance extends equipment life, reduces downtime, decreases repair and operational costs, lowers accident risks, and streamlines operations. While you may be taking measures to ensure proper maintenance, using predictive maintenance techniques will take your efficiency to the next level.

Predictive maintenance software uses can use tools like machine learning to determine the condition of your equipment and predict when potential problems may occur. This information allows your team to take preventive measures and correct the flagged issues.

3. Quality Control and Assurance

Quality control and assurance are processes that keep your plant in line with your product and service expectations and regulatory requirements. Quality control also plays a role in efficiency. Some of the popular techniques you can employ to monitor and maintain quality for improved efficiency include:

Cause-and-effect diagram
Control chart
Check sheet
Histogram
Stratification

Quality control and assurance can help you oversee and improve performance and effectiveness throughout the manufacturing process, resulting in higher overall equipment effectiveness.

Effective Inventory and Time Management

Combining inventory management and time management can help improve efficiency on the production floor. Here’s a breakdown of these two considerations:

Inventory Management Techniques

Maintaining overall efficiency in your facility requires a strategy for managing inventory, such as using smart systems for digital inventory tracking. These systems should improve reaction to market changes, allowing you to adjust stock levels and other aspects of the supply chain. Digital solutions like automated inventory management software can streamline the supply chain through capabilities like demand planning, mobile integration and barcode scanning.

These strategies can improve stock efficiency, eliminating overstocks and stockouts. You’ll know when to use bulk quantities to boost cost savings and maintain supply.

Time Management Strategies

Inventory management is closely linked to time management. With efficiency principles like just-in-time inventory management, also known as lean management principles, your plant can strike a fluid balance between production volume and inventory levels, allowing you to free up cash flow and labor. As a result, you improve costs and save time.

In addition, your facility can improve time management during operations by training employees on effective time management. Key components of time management include staying organized, working as a team, communicating clearly and prioritizing value-added tasks.

Contact Meritus Gas Partners for Industry Solutions

Understanding how to improve efficiency in manufacturing can be the key to your facility’s success. Overall, you want to consider automation technologies, predictive systems, quality control and inventory and time management practices to make the most impact.

Given today’s unpredictable industry demands, working with a solution-driven partner can be the tool you need to strengthen your operations and maintain growth. At Meritus Gas Partners, we support our customers with resources and corporate services to help them deliver.

Having access to a reliable manufacturing distributor, whether you need materials processing gases or safety equipment, is a key part of creating a more efficient facility. Learn more about our network of partners and contact us to get started with industry-specific solutions.

Collaborative robots, also known as cobots, have revolutionized the manufacturing industry with their intuitive programming, affordability and barrier-free operation. Their use in the manufacturing sector continues to rise, thanks to their ability to automate material handling, material removal, maintenance, quality control and more functions.

The collaborative robot market was valued at $1.2 trillion in 2023 and is projected to triple by 2030. Having these robots on your team is a cost-effective way of increasing productivity. However, to ensure they work as expected and you can reap their benefits, you need to maintain them properly.

Why Maintaining Your Cobot Matters

Like any other machine or equipment, robots require preventive maintenance. Reliability and precision are non-negotiable in the manufacturing industry, and you want your robots to always produce the expected results.

Regularly conducting preventative maintenance will help you avoid issues that can affect the cobot’s performance. Specifically, preventative maintenance can address the following issues:

Software breakdown: Uncontrolled loss of programs and vital information.
Position deviation: When the robot fails to perform within the intended parameters.
Safety issues: Cobot behaviors that are unpredictable and can cause injuries.
Cable damage: Issues with data cords and power, cables and wires, which may be fire hazards.

Signs That a Cobot Needs Maintenance

Performing preventative maintenance can lower the chances of your cobot breaking down or showing signs of damage. As a result, neglecting this maintenance means the robot may break down when you least expect it. The following signs can indicate that your cobot needs maintenance or repair:

Energy drain: If a cobot starts consuming more power than usual, it could be a sign of damage, and maintenance may be needed.
Uncommon sounds: Pay attention to the type of sound the cobot produces. If you notice anything unusual, inspect the robot to identify the problem.
Obvious damage: If you notice any damage to the cobot’s parts, such as the cable, sensor or arm, you should make repairs.
Inconsistencies and repetitions: When the cobot can’t consistently make repetitive motions, it’s a major concern for both productivity and safety reasons. Erratic movements can cause injuries to employees.
Software challenges: Software glitches may affect a cobot’s performance. These software issues are easy to identify. 

If it’s been a long time since you last maintained the cobot, you don’t need to see any signs to do maintenance. You should inspect the cobot as soon as possible and perform maintenance if necessary. At that point, it’s important to establish a routine maintenance plan so you can prioritize the care of your cobot.

Developing and Following a Comprehensive Cobot Maintenance Plan

Without a scheduled plan, skipping or forgetting preventative cobot maintenance is easy. This is why you should have a maintenance plan that includes scheduled periods when specific types of maintenance are required. Take the following steps to develop, follow and update your plan:

Assess the cobot’s needs: Identify maintenance requirements that are specific to the type of cobot you have — check the manufacturer’s recommendations for information. Additionally, consider your work environment and how it might affect maintenance. For example, a cobot that operates in busy conditions may need more frequent lubrication and cleaning.
Prepare a maintenance schedule: Create a checklist or calendar that reminds you when to perform specific types of maintenance. The schedule may include daily, weekly, monthly, quarterly and annual checks and maintenance.
Perform maintenance according to schedule: Follow and adhere to the scheduled maintenance plan you prepared, ensuring you and your team don’t skip any checks. Use the appropriate materials and tools for your cobot’s maintenance. Whoever is doing the maintenance should wear protective gear to avoid injuries or damage to the cobot.
Review the maintenance plan: Maintenance ensures the cobot always works optimally. Your plan should include evaluations to check the efficiency and effectiveness of the maintenance you’ve been doing. Does the machine still break down even after regular maintenance? Are you performing the appropriate maintenance? Are there areas that need improvement? You should also seek feedback from cobot users after doing maintenance.
Educate yourself and others about maintenance: Educate other team members on how to maintain the cobot properly. You should also update yourself on the latest developments in robotics to implement new and effective maintenance methods as they arise.

General Cobot Maintenance Tips to Follow

As part of your maintenance plan, you’ll want to include specific checks and tests to ensure the cobot is operational and identify any issues. The specific repairs you do will depend on your cobot’s make and model, so always consult the operator’s manual to form the foundation of your approach. However, general checks like the following are also important:

Perform Daily Visual Checks

Perform daily visual checks on the cobot for any possible damage or signs of impending damage. This step should be an integral part of your team’s process so you can identify potential issues quickly and before they worsen. For example, you or a team member can visually check the cables and bolts to make sure they’re configured properly

Conduct Software Updates

Regular software updates are crucial to ensure the safety of the cobot. In addition, software updates allow for the addition of new operational features. Check out your manufacturer’s recommendations on software updates. A software update may include features that make it easy to diagnose and troubleshoot your cobot and provide the ability to export logs to the manufacturer’s customer support.

Ensure Proper Airflow

Proper airflow is required in a cobot’s controller to prevent overheating, which can cause damage. This damage may compromise the robot’s life span. Clean the cooling fans every three or so months to avoid overheating and keep your cobot running properly for longer.

Clean Sensors and Optics Regularly

Optics and sensors are crucial vision tools for cobots. Cobots rely on these tools to move, pick up items and drop them. Ensure the sensors and optics are clean and free of debris or dirt to ensure the cobot’s performance isn’t compromised. Dirty or poorly maintained optics may also make the cobot unsafe to use.

Work With Qualified Technicians

When you need repairs done on the cobot, work with qualified and authorized personnel who can do the work properly and professionally. Attempting to do the work yourself without the right knowledge can result in cobot damage or safety issues for yourself. It’s always better to invest in expert assistance when it comes to maintaining your equipment.

In recent years, the manufacturing industry has witnessed a remarkable transformation with the integration of cutting-edge technologies. One innovation that is reshaping the landscape of welding is the introduction of collaborative welding robots, often referred to as COBOTs. These sophisticated machines are changing the game by combining the precision of robotic welding with the adaptability of human workers.

Understanding Collaborative Welding Robots

Wondering what a collaborative welding robot even is? COBOTs are robotic systems designed to work alongside human operators in a shared workspace. Unlike traditional industrial robots that require isolated environments and safety barriers, collaborative robots are equipped with advanced sensors and safety features that enable them to collaborate with human workers without compromising safety.

Key features of collaborative welding robots and how they function:

Sensors and Vision Systems

Collaborative welding robots are equipped with a range of sensors and vision systems that allow them to perceive their environment. These sensors enable the robots to detect the presence of humans and other obstacles in real-time, ensuring a safe working environment. Vision systems enhance their ability to accurately locate welding joints and adapt to variations in workpieces.

Safety Features

Safety is paramount when humans and robots share a workspace. COBOTs are designed with safety features, such as force and torque sensors, that allow them to detect unexpected contact and immediately halt their movements. This ensures that human workers are protected from any potential accidents.

User-Friendly Interfaces

COBOTs are designed to be user-friendly, with intuitive interfaces that allow even non-experts to program and operate them. This democratization of robot programming enables quick integration into existing manufacturing processes without requiring extensive training.

Adaptive Programming

Unlike traditional industrial robots that follow pre-programmed paths, COBOTs can adapt to changes in the environment and workpiece. This adaptability is crucial in dynamic manufacturing settings where variations in product design or production requirements are common.

5 Ways COBOTs Impact the Welding Industry

COBOTs are poised to have a profound impact on the welding industry by increasing efficiency, improving quality and consistency, enhancing safety, bringing flexibility to the production process and cutting costs.

Increased Efficiency: Collaborative welding robots enhance efficiency by automating repetitive and labor-intensive welding tasks. Human operators can focus on more complex aspects of the welding process, such as quality control and problem-solving, while the robots handle routine tasks with precision.
Improved Quality and Consistency: The precision and repeatability of collaborative welding robots contribute to improved weld quality and consistency. With the ability to maintain a consistent welding speed and accuracy, these robots help reduce defects and ensure a high level of product quality.
Enhanced Safety: Safety is a top priority in manufacturing, and collaborative welding robots are designed with this in mind. By working alongside human operators and employing advanced safety features, these robots minimize the risk of accidents and create a safer working environment.
Flexibility in Production: COBOTs can easily be reprogrammed to handle different welding tasks and adapt to changes in production requirements. This agility is particularly valuable in industries where product designs and specifications frequently evolve.
Cost Savings: While the initial investment in collaborative welding robots may be significant, the long-term benefits often outweigh the costs. Increased efficiency, reduced errors, and improved productivity contribute to significant cost savings over time.

All in all, COBOTs are revolutionizing the welding industry by combining the strengths of automation with the adaptability of human workers. The collaborative future of welding is here, bringing with it a new era of innovation and opportunity for the manufacturing industry. Are you ready?

Request a Quote on a COBOT

Is COBOT Right for Your Shop?

Atlas Welding Supply is excited to offer the Mod-Weld COBOT from APT Manufacturing. After careful consideration of many options, we chose APT as its preferred COBOT provider. We believe the Mod-Weld is an extremely robust and intelligent design. It is fully customizable at a competitive price point. You can specify the table size and shape, power supply size and configuration, shelves, drawers and accessories.

Industry Best Features:

FANUC CRx Collaborative Robot
8 years to 1st scheduled maintenance
IP 67 COBOT rating

Additional Features:

Mobile cart welded construction powder coat finish
APT Clever Torch teach button software package ready to teach and weld
Lockable teach tablet holder
Top plate 40 in x 58-1/2 in with 16mm on center holes for clamping and fixture hold down
6 in casters for ease of movement
Ready to accept side cart and accessories

Power Supply Options:

Miller Continuum
Fronius TPS/i

Start Your COBOT Journey Atlas Welding Supply!

We are here to help you through the process of deciding if COBOT belongs in your shop! Contact us to schedule a call with our Productivity Specialist, ask questions or see a virtual demo.