Automotive Chassis Welding Line Robotization

🎯 Challenge / Goal

Customer's existing manual welding line only produced 120 parts/day with an 8% defect rate due to operator-dependent quality. Finding night-shift welders was increasingly difficult and workplace accident risk was high.

⚙️ Solution Applied

CFS team optimized robot cell layout via RobotStudio 3D simulation. Safety zones and interlocks were engineered with Siemens S7-1500F Safety PLC. Each robot tower is equipped with Fronius CMT welding systems. WinCC Unified SCADA delivers OEE dashboards, part traceability and seam-quality analytics powered by inline vision inspection.

📈 Results

• ✓Production capacity: 120 → 320 parts/day (+167%)
• ✓Defect rate dropped from 8% to 1.2%
• ✓OEE improved from 62% to 89%
• ✓Workplace accident risk eliminated
• ✓Annual cost savings of $320,000

🔧 Technologies Used