Flexible Robotic Welding Solution for Maximum Product Diversity in Contract Manufacturing

Client: N&S Schweißtechnik

Challenge

German contract manufacturer N&S Schweißtechnik required a modern robotic welding solution capable of economically handling an exceptionally wide product mix in small batch production. At the same time, the new system had to be adapted to the limited space available in an existing production hall and significantly increase productivity compared to older robotic welding systems.

Solution

By implementing two Panasonic TAWERS welding cells, a PA-ET-2DK cell with rotary table and a PA-TT-2DK cell with two workstations and two tilt-rotary positioners, a highly flexible automation solution for high-mix, low-volume manufacturing was realized. Through a customized cell layout adapted to the available floor space and the reduction of non-value-added time, the company increased productivity, secured new business, and expanded its product portfolio.

Greater Flexibility and New Business Opportunities Through Advanced Robotic Welding Technology

For many manufacturers, automation primarily means the economical production of high volumes. For N&S Schweißtechnik, this was also important, but another challenge had to be addressed: the cost-effective production of a large variety of different products in small batch sizes.

The welding service provider mainly manufactures individual parts and small- to large-scale production series for customers in the material handling, aerospace, shipbuilding, mining, and environmental technology sectors. Applications range from delicate components with material thicknesses of only one millimeter to heavy-duty industrial parts.

Products manufactured by the company include shock absorbers for cranes and trucks, conveyor rollers for material handling systems, connector elements for aircraft armrests, cylinder end caps for offshore applications, spring brake accumulators for shipbuilding, and wear-resistant components for waste incineration plants and mining operations.

"Our production is characterized by an enormous variety of products. Hardly any order is the same as the next. That's why we need a welding solution flexible enough to adapt quickly to new components and changing requirements."

Existing Robotic Systems Had Reached Their Limits

The robotic welding systems previously in use had been operating for many years and were no longer able to fully meet the demands of modern contract manufacturing. In particular, loading and unloading times significantly reduced productivity.

At the same time, the production environment imposed specific requirements on the design of a new automation solution. The production hall offered only limited floor space, while the low roof structure further complicated the integration of new robotic welding cells.

The company therefore sought a solution that would provide maximum flexibility, increase productivity, and integrate seamlessly into the existing manufacturing environment.

Customized TAWERS Welding Cells

Working together with Panasonic, N&S Schweißtechnik developed a customized automation solution based on TAWERS technology and tailored to the site's specific spatial constraints.

Today, two Panasonic robotic welding cells are in operation. Larger components are processed in a PA-ET-2DK cell with a rotary table, while a PA-TT-2DK cell featuring two workstations and two tilt-rotary positioners is specifically designed for the efficient processing of smaller and frequently changing workpieces.

Due to the limited ceiling height, the entire cell concept was individually adapted. Despite the restricted installation space, extraction systems, maintenance access points, and service doors were optimally integrated.

The combination of rotary-table and changeover-table concepts significantly reduces non-productive time. While welding is carried out on one side, new components can already be prepared on the other. This maximizes cell utilization and sustainably increases productivity.

Another key advantage is the high flexibility of the Panasonic solution. The robots perform both tack welding and final welding operations and can be reconfigured quickly for new parts, a decisive factor for N&S Schweißtechnik.

One System for a Wide Range of Applications

Today, the two Panasonic robotic welding cells are used for an exceptionally broad range of applications.

The product spectrum ranges from shock absorbers for cranes and trucks with material thicknesses from 1 to 30 mm, and conveyor rollers for material handling systems, to connector elements for aircraft armrests with particularly stringent tolerance requirements.

Additional applications include cylinder end caps for offshore environments, spring brake accumulators for shipbuilding with diameters ranging from 100 to 600 mm, hardfacing applications for components used in waste incineration plants, and hydraulic cylinders for the mining industry. Even welding operations on anchor chains up to 800 meters in length are part of the application portfolio.

The robust and reliable Panasonic welding torch demonstrates particular strengths when processing heavy components. Many workpieces feature large and long weld seams that are welded using a high-capacity 500 A torch. In difficult-to-access welding areas and confined geometries, a 400 A torch is used to provide improved accessibility.

The systems also operate 24/7 in a three-shift environment. With welding currents of up to 350 A and short cycle times, they reliably and consistently handle even demanding welding applications.

Significantly Increased Productivity and Expanded Capabilities

Since commissioning the Panasonic solution approximately six years ago, the company has achieved substantial and lasting improvements in its production processes.

The increased flexibility has also enabled the economical production of new product groups. In particular, smaller components with shorter production cycles could be added to the company's offering.

The result: additional orders, new customer projects, and a continuous expansion of the company's service portfolio.

The solution also delivers benefits in workforce utilization. For larger components, a single operator can now supervise two robotic welding systems simultaneously, further improving overall production efficiency.

A Reliable Partnership Over Many Years

For the company, the project did not end with commissioning. During ongoing operations, the customer continues to value the close collaboration with Panasonic. Fast service response, direct communication channels, and practical training programs have helped ensure that both robotic welding cells have been operating reliably and economically for more than six years.

"With the Panasonic solution, we have significantly increased our productivity. Above all, the reduction in non-productive time makes a tremendous difference in day-to-day operations. As a result, we have been able to secure additional orders and expand our portfolio."

Looking Ahead

The positive experience with the robotic welding cells forms the foundation for the next phase of expansion. A third system is already being planned to create additional capacity and further increase manufacturing flexibility.

In addition, DTPS (Desk-Top Programming & Simulation System) may be introduced to support production planning. This would enable key performance indicators such as cycle times, energy consumption, and manufacturing costs to be simulated and optimized in advance.

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Flexible Robotic Welding Solution for Maximum Product Diversity in Contract Manufacturing

Challenge

Solution

Existing Robotic Systems Had Reached Their Limits

Looking Ahead

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