Tier-1 Automotive Supplier Increases Welding Throughput 300%
Multi-robot welding cell delivers 45-second cycle time for complex suspension components
Project Overview
A leading Tier-1 automotive supplier approached AMD Automation with a critical capacity challenge. Their suspension control arm production line was bottlenecked at the welding station, where skilled manual welders could only produce 120 parts per shift—far short of the 400+ parts their OEM customers now required.
The stakes were high: failure to meet demand would mean lost business worth over $15M annually.
Engineering Approach
Our engineering team conducted a thorough analysis of the existing process, identifying several key opportunities:
Part Analysis
The control arm required 14 individual welds across multiple planes. Manual welders were spending significant time repositioning parts and could only weld one joint at a time.
Process Optimization
By designing a custom H-frame positioner with dual fixtures, we enabled: - Loading/unloading on Station A while robots weld on Station B - Both robots welding simultaneously on opposite sides of the part - Automatic rotation to present all weld joints without operator intervention
Quality Integration
Laser seam tracking eliminated the primary source of manual weld defects—inconsistent torch positioning due to stamping variation. Real-time monitoring flags any welds outside specification before the part leaves the cell.
Implementation
The project was executed in phases to minimize production disruption:
Phase 1 (Months 1-3): Engineering, robot simulation, and fixture design Phase 2 (Months 4-5): Fabrication and assembly at AMD facility Phase 3 (Month 6): Factory Acceptance Testing with customer parts Phase 4 (Months 7-8): Installation, commissioning, and production ramp
The cell achieved full production rate within 30 days of installation, ahead of the 60-day target.
Customer Testimonial
"AMD Automation delivered exactly what they promised—a turnkey solution that tripled our capacity without adding floor space. The quality improvement was an unexpected bonus that's saving us significant rework costs."
— Operations Director, Tier-1 Automotive Supplier
01The Challenge
The client was struggling to meet increasing demand for suspension control arms. Their existing manual welding operation could only produce 120 parts per shift, while customer requirements had grown to 400+ parts per shift.
- Manual welding limited to 120 parts per 8-hour shift
- Inconsistent weld quality causing 8% rejection rate
- Skilled welder shortage making it difficult to add capacity
- Floor space constraints limiting expansion options
- Need to maintain production during installation
02Our Solution
AMD Automation designed a compact dual-robot welding cell with an integrated rotary positioner that maximizes floor space utilization while enabling continuous production through load/unload during welding cycles.
Dual FANUC Arc Mate Robots
Two coordinated welding robots working simultaneously on opposite sides of the part, cutting cycle time in half compared to single-robot approaches.
H-Frame Rotary Positioner
Custom-designed positioner with dual fixtures allows loading/unloading on one side while welding on the other, eliminating non-value-added time.
Lincoln Power Wave Welding
Advanced pulse MIG welding with WeldCloud monitoring ensures consistent penetration and minimizes spatter on zinc-coated steel.
Vision-Guided Seam Tracking
Laser seam tracking compensates for part variation, maintaining weld placement within ±0.5mm despite stamping tolerances.
03The Results
The new cell exceeded all performance targets within 30 days of production start, enabling the client to meet customer demand while reducing labor costs and improving quality.
Technical Specifications
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