Page 100 - MetalForming October 2015

Robotic Welding Cells
...and in with the new at Ariens Co., where several new automated welding cells have spurred a 25-percent leap in productivity, while slashing the time lost to maintenance, repairs and tech calls.
At the turn of the century, Bril- lion, WI-based Ariens Co. began practicing the principles of lean manufacturing, and it’s been an impor- tant part of daily life at the company ever since. So when Ariens began expe- riencing problems with its robotic- welding cells, management quickly went in search of a solution to ensure that productivity remained high, while the reins remained tight on downtime and service calls.
More than 5000 Annual Service Calls
Ariens has long used robotic welding on the manufacturing floor, but in recent years its aging robotic-welding cells became plagued with breakdowns and downtime for service. Its robotic tech-support department averaged more than 5000 tech calls for robotic weld-cell breakdowns annually, with each call averaging 13 min.
“When some of the older cells crashed, they were down for hours,” says Ariens team leader Ron Heiting.
The company also experienced issues with the availability of service, support and parts for maintenance and repair.
“We had many instances where we’d lose a day or two of production because we were unable to get replacement parts,” says Ariens electrician Jeremy
Thanks in no small part to relief robotic-welding cells taking the place of aging and unreliable cells, Ariens continues to churn out snow blowers and other outdoor power equipment at a great clip. In fact, the company recently announced plans for a $9-million upgrade and 45,000-sq.-ft. expansion of its product-development center in Brillion, WI, slated for completion by the fall of 2018.
Foytik. “If we did find parts, often the price was astronomical.”
A Customized Solution
In search of a solution, Ariens sent several employees to visit with robotic- equipment manufacturers, bringing
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with them sample parts and fixturing. In the end, the firm elected to invest in new PerformArc robotic-welding cells from Miller Electric Mfg. Co.—five Per- formArc 350 systems and one Per- form-Arc 750. The 350 boasts a com- pact 7- by 14-ft. footprint and features