How Cobot Welding Cells Mitigate the Welder Shortage and Boost Productivity

The welding industry is essential to modern manufacturing, but it's currently facing a significant challenge: a shortage of skilled welders. In the U.S., the average welder is 55 years old, and only a small percentage of welders are under 35. This aging workforce means we could face a shortage of 330,000 welders by 2028. The gap is widening as fewer young people choose welding as a career, often seeing it as a monotonous and less rewarding job.

Despite these challenges, welding remains critical to manufacturing across industries like automotive, aerospace, and construction. The growing demand for skilled welders is at odds with the shrinking workforce, threatening to disrupt production and compromise product quality.

To address this challenge, collaborative robots, or cobots, are becoming increasingly popular. Unlike traditional industrial robots, cobot welding cells are designed to work alongside human workers. They are smaller, more flexible, and easier to program, making them ideal for small to medium-sized companies. Cobots can take on repetitive welding tasks, allowing human welders to focus on more complex and valuable work. This not only boosts productivity but also helps make the welding profession more attractive.

Now, let's explore the specific challenges faced by the welding industry, beginning with the welder shortage.

Challenges of the Welding Industry

Welder Shortage Situation

The welder shortage in the United States is a pressing issue, deeply rooted in demographic trends and changing career preferences. The median age of welders is currently 55, with only 20 percent of welders under 35 and more than 159,000 welding professionals approaching retirement. 

One of the main reasons for this shortage is that young people are increasingly reluctant to pursue welding as a career. They often see it as monotonous, dirty, and not well-paying compared to other professions. Moreover, there’s a strong societal push towards college education, which diverts potential talent away from vocational trades like welding. The long-term implications are significant: without enough skilled welders, manufacturing processes could slow down, affecting the production of everything from cars to infrastructure, and potentially leading to higher costs and reduced competitiveness for U.S. manufacturers.

High Welding Costs

Welding is not just labor-intensive; it can also be expensive. The main cost drivers in welding include labor, post-weld operations, non-value-added tasks, and reject/rework/scrap costs. Labor is the biggest expense, often accounting for up to 85% of welding costs. High labor costs make it crucial to optimize welders’ time and efficiency to stay competitive.

Post-weld operations, such as grinding and finishing, add to the costs by consuming additional time and resources. Non-value-added tasks, like moving materials around or waiting for equipment, further inflate expenses without contributing to productivity. Moreover, defects in welding can lead to costly rework or scrap. Early detection of these defects is essential to minimize these costs. Implementing process optimizations, such as cleaner welds and streamlined workflows, can significantly reduce these expenses, making operations more efficient and cost-effective.

The Need to Increase Productivity

In the competitive welding industry, increasing productivity is vital for profitability. Human welders, despite their skills, have limitations that can impact consistency and lead times. Factors like fatigue and varying skill levels can result in inconsistent weld quality, which in turn affects productivity. Even the best welders can have off days, leading to delays and increased costs.

Improving productivity means ensuring consistent quality and minimizing downtime. One way to achieve this is by identifying and eliminating bottlenecks in the welding process. For instance, replacing processes that cause unnecessary delays or improving quality control to reduce defects can boost productivity. By streamlining operations and using tools like cobots to handle repetitive tasks, manufacturers can maintain high productivity levels and improve their bottom line.

Quoting Challenges: Costs and Lead Times

Accurately quoting welding jobs is a challenge due to the variability in human performance. Calculating the cost and time required for welding tasks relies heavily on human factors, which can be unpredictable. This unpredictability can lead to delays and longer lead times, frustrating clients and potentially resulting in lost contracts.

Clients expect timely delivery and precise cost estimates, but the inherent variability in manual welding makes this difficult. Delays, whether from fatigue, errors, or unforeseen issues, can wreak havoc on production schedules. To mitigate these challenges, manufacturers need reliable methods to estimate welding costs and lead times. Using cobots to handle repetitive tasks can help stabilize production schedules and provide more accurate quotes, enhancing client satisfaction and improving the likelihood of retaining contracts.

Automated Welding

As the welding industry grapples with these significant challenges, automated welding presents a promising solution. Leveraging robotics in welding can address many of the issues related to labor shortages, high costs, and the need for increased productivity. However, it’s important to understand that not all robotic solutions are the same, especially when it comes to the diverse needs of small to medium-sized companies.

Not All Robotic Solutions are the Same

When considering automated welding, it's crucial to distinguish between traditional industrial robots and collaborative robots (cobots). Traditional industrial robots are designed for high-volume, repetitive tasks and are often used in large-scale manufacturing operations, such as automotive production. These robots are typically large, expensive, and require extensive programming and safety measures, including safety fences to keep human workers at a distance. This makes them less ideal for smaller operations and environments that need flexibility.

On the other hand, collaborative robots are designed to work alongside human operators in a shared workspace. Cobots are smaller, more flexible, and easier to program, which makes them perfect for small to medium-sized companies. They are particularly suited for high-mix, low-volume production environments where versatility and adaptability are key. Unlike traditional industrial robots, cobots do not require extensive safety barriers, making them easier and less costly to integrate into existing workflows.

Cobots can take over repetitive welding tasks, reducing the physical strain on human workers and allowing them to focus on more complex and skilled aspects of the job. This not only helps in addressing the labor shortage but also improves overall productivity and job satisfaction. By integrating cobots into their operations, manufacturers can achieve a balance between automation and human expertise, leading to more efficient and adaptable production processes.

What are Collaborative Robots?

Collaborative robots, or cobots, are a type of robot designed to work safely alongside human workers in a shared workspace. Unlike traditional industrial robots, which are typically large, rigid, and confined to specific areas due to safety concerns, cobots are smaller, more flexible, and equipped with advanced safety features that allow them to operate in close proximity to humans.

One of the key differences between cobots and traditional industrial robots is ease of use. Cobots are designed to be user-friendly, often featuring intuitive programming interfaces that do not require extensive robotics knowledge. This makes them accessible to small and medium-sized companies that might not have the resources to hire specialized robotics engineers. Cobots can be quickly reprogrammed for different tasks, making them ideal for high-mix, low-volume production environments where versatility is crucial.

Another significant advantage of cobots is their safety features. They are equipped with sensors and force-limiting technology that allow them to detect and react to human presence, minimizing the risk of accidents. This safety aspect eliminates the need for extensive safety barriers, reducing installation costs and space requirements. Overall, cobots offer a flexible, cost-effective, and safe automation solution for a wide range of manufacturing tasks.

Benefits of Welding With a Collaborative Robot

Welding with a collaborative robot offers numerous benefits that can transform welding operations. Here are some of the key advantages:

• Cost Savings: Cobots can significantly reduce labor costs by taking over repetitive and time-consuming welding tasks. They also minimize errors and reduce waste, leading to lower overall production costs.
• Increased Productivity: Cobots can operate continuously without fatigue, ensuring consistent weld quality and faster production times. This allows human welders to focus on more complex and skilled tasks, enhancing overall productivity.
• Flexibility: Cobots are ideal for high-mix, low-volume production environments. They can be easily reprogrammed and adapted to handle different welding tasks, making them a versatile addition to any manufacturing operation.
• Constant Quality: Cobots provide consistent weld quality, eliminating the variability associated with human welders. This ensures high standards are maintained throughout the production process.
• Ease of Installation and Maintenance: Cobots are designed to be easy to install and maintain. Their user-friendly interfaces mean that even operators with minimal technical knowledge can set them up and keep them running efficiently.

ROI: Getting The Most Out of Your Cobot

Calculating the Financial Aspect of Your Welding Cobot

When considering the implementation of a welding cobot, it’s important to understand the total cost involved. The initial investment includes not just the cost of the cobot itself, but also several other factors such as jigs and fixtures, engineering, programming, and installation.

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1. Cost of the Robot: The cobot is usually the primary expense. Prices can vary depending on the brand, capabilities, and additional features.
2. Jigs and Fixtures: To ensure precise and consistent welding, you’ll need to invest in jigs and fixtures that hold the parts in place. These are crucial for repeatable accuracy and efficiency.
3. Engineering and Programming: While cobots are easier to program than traditional robots, there may still be costs associated with customizing the cobot to fit your specific needs. This can include programming the cobot to perform particular tasks and integrating it into your existing systems.
4. Installation: The installation process should be straightforward with a cobot, but there might be some costs related to setting up the work area, especially if it involves reconfiguring.

To estimate the productivity gains, consider how many shifts the cobot will work. Cobots can operate continuously, so calculate the number of hours per shift and multiply by the number of shifts per day. Also factor in the number of working days in a week and weeks in a year to get a clear picture of the potential productivity.

Calculate the Return on Investment

• Labor Cost Savings: The most significant variable is the savings on labor costs. Calculate the annual labor cost for a human welder, including salary, benefits, and insurance. Compare this with the cost of operating a cobot.
• Maintenance Costs: Cobots generally have lower maintenance costs compared to traditional industrial robots. Factor in the minimal maintenance required to keep the cobot running efficiently.
• Team Development: Consider the cost of training your team to operate and maintain the cobot. While this may be an initial expense, it’s crucial for long-term efficiency and productivity.
• Productivity Gains: Estimate the increase in productivity due to the cobot’s ability to work without breaks, produce consistent quality, and reduce downtime. Higher productivity often translates to more completed jobs and higher revenue.
• Intangibles: These are benefits that don’t have a direct monetary value but significantly impact the ROI. Consider factors like:
  • Production Stability: Consistent quality and fewer defects lead to a stable production process.
  • Employee Safety: Reducing the exposure of workers to hazardous environments can lead to lower health-related costs and improved morale.
  • Improved Efficiency: By freeing up skilled welders to focus on more complex tasks, overall operational efficiency improves.
  • Customer Satisfaction: Consistent quality and reliable lead times enhance customer satisfaction, leading to repeat business and positive referrals.

To calculate the ROI, use the formula:

ROI = Total Savings per Year / Total Costs

The goal is to achieve a realistic ROI period, typically aiming for a return within two years. Including both tangible and intangible benefits in your calculations provides a comprehensive view of the financial impact and overall value of investing in a welding cobot.

How To Get Started With a Welding Robot - Step by Step

Getting started with a welding robot can seem daunting, but breaking it down into manageable steps can simplify the process. Here’s a step-by-step guide to help you integrate a welding cobot into your operations successfully.

Get Everybody On Board and Set Your KPIs

• Gather Your Team: Start by bringing your team together to discuss the introduction of the cobot. Address any concerns and explain the benefits of automation.
• Set Key Performance Indicators (KPIs): Establish clear goals to measure the success of the cobot integration. KPIs might include productivity levels, weld quality, and reduction in downtime. Having defined metrics helps track progress and make adjustments as needed.

Decide on Which Task to Automate

• Analyze Your Workflow: Look at your current welding processes and identify tasks that are repetitive and time-consuming. These tasks are ideal candidates for automation.
• Consider Complexity and ROI: Start with simpler tasks that offer a high return on investment. Once you gain experience and confidence, you can automate more complex processes.

Start Small First

• Pilot Project: Begin with a pilot project to test the cobot in a controlled environment. This helps identify any potential issues and allows for adjustments before full-scale implementation.
• Build Expertise: Use the pilot project to build your team’s expertise and confidence in working with the cobot. Gradually scale up as you become more comfortable with the technology.

Preparing the Jigs and Fixtures

• Design and Create Jigs: Ensure you have the necessary jigs and fixtures to hold parts in place during welding. These should be designed for repeatability and accuracy.
• Consult Experts: If you lack the resources to create these in-house, consider outsourcing to a machine shop or consulting with your cobot supplier for recommendations.

Choose Your Welding Cobot Solution

• Evaluate Options: Research different welding cobot solutions available in the market. Look for cobots that offer ease of use, flexibility, and good customer support.
• Demo the Cobot: Whenever possible, arrange for a demonstration to see the cobot in action. This will help you assess its suitability for your specific needs.

Train Your Welders

• Comprehensive Training: Ensure your welders receive thorough training on how to operate and maintain the cobot. This can often be facilitated by the cobot supplier.
• Documentation: Document the training process to ensure that knowledge is retained within the organization, even if the primary operator leaves.

Troubleshoot, Optimize, Repeat

• Initial Troubleshooting: As the cobot begins operations, monitor its performance closely. Address any issues promptly and make necessary adjustments.
• Continuous Optimization: Regularly review the cobot’s performance against your KPIs. Optimize the processes and workflows to ensure you are getting the best results.
• Iterative Improvement: Automation is an ongoing process. Continuously look for areas where the cobot can add more value and efficiency to your operations.

By following these steps, you can smoothly integrate a welding cobot into your production process. This structured approach ensures that you address potential challenges early, optimize performance, and maximize the benefits of automation.

Introduction to the Spartan Welder

Key Features and Benefits:

• Ease of Deployment: The Spartan Welder is designed for quick and straightforward deployment. Its user-friendly interface and intuitive programming enable even those new to robotic welding to get started with minimal training.
• Enhanced Flexibility: With its 7th axis, the Spartan Welder can handle intricate welds and reach challenging areas. This flexibility is particularly beneficial in high-mix, low-volume production environments.
• Superior Components: Incorporating premium components ensures reliable performance and high-quality welds.
• Cost-Effective Solution: Despite its advanced features, the Spartan Welder is priced the same as other 6-axis cobot welding cells. Additionally, there are no recurring software costs, it can be financed for quicker ROI, and it qualifies for Section 179 deduction, making it a financially smart investment.
• Minimal Maintenance: Designed for easy maintenance, the Spartan Welder reduces downtime and keeps your production line running smoothly.

By integrating the Spartan Welder into your operations, you can achieve higher productivity, improved weld quality, and greater flexibility. This advanced cobot is tailored to meet the unique needs of modern manufacturing, providing a reliable and efficient solution to the challenges faced in welding operations.

Ready to see how the Spartan Welder can transform your welding operations? Book a virtual demo today to discover the benefits of our advanced cobot welding solution. Experience firsthand how the Spartan Welder can help you achieve greater productivity, improved quality, and reduced costs. Contact us now to schedule your demo and take the first step towards a more efficient and automated welding process.