The Challenge
High‑Volume Spot Welding with Consistent Quality and Minimal Labor
The customer faced several operational challenges that prompted MWES engagement:
- Manual welding introduced variability in weld placement and quality
- Labor shortages and lack of trained welders limited production scalability
- Automotive part tolerances required consistent cyclical welding
- The baffle assembly needed to be completed in under 10 seconds per part
MWES was selected to apply its expertise in resistance-spot welding systems for demanding automotive manufacturing environments.
The Solution
Dual Dial-Table Cell with Automated Spot Welding and Reject Handling
MWES engineered two fully enclosed welding cells that operate in parallel and include:
- Six-station indexing dial systems for both louver and diverter welding modules
- Dual Milco C‑type resistance weld guns at each weld station to apply consistent spot welds
- Fixture-based part holding optimized for accuracy and repeatability
- Integrated pneumatic unloading and reject chutes to manage good and scrap parts
- HMI-based control and automated cycle sequencing to ensure reliable throughput
This spot-welding automation delivers rapid, consistent weld application and reduces operator dependency while maintaining high-volume output.
The Results
One Weld Every Ten Seconds,700K+ Parts Annually, Minimal Labor
Implementation realized substantial performance and quality improvements:
- Capable of welding over 800,000 parts per year, or one complete part every 10 seconds
- Eliminated manual weld labor and associated fatigue or inconsistency
- Achieved high-repeatability weld placement across long production runs
- Seamlessly integrated into existing cell layout without requiring new tooling or infrastructure
By replacing manual spot welding with automated dial-table cells and precision resistive welding, MWES dramatically increased throughput and quality, while minimizing labor involvement.
