Problems in Welding Work：Why Do We Need Welding Robots?
Welding is never an easy job that "anyone can do with a welding torch". Welders need to stay highly focused and have good skills. They also have to face many hidden risks in this job all the time.
For manufacturing companies, the problems caused by manual welding can easily become an invisible obstacle to development.
For manufacturing companies, the problems caused by manual welding can easily become an invisible obstacle to development.
What are the main problems with manual welding?
Many factory owners and production managers know well about the problems of manual welding. These problems seem to happen in the workshop, but they will finally hurt the company’s core interests:
Late order delivery harms relationships with customers;
Companies cannot take all the extra orders in peak seasons, so they lose business;
Unstable welding quality leads to frequent customer complaints, which makes customers trust less and damages the company’s reputation;
Production capacity can never keep up with market demand, so the company loses more market share and competitiveness.
There are four main problems behind these operational troubles in manual welding.
Four Main Problems of Manual Welding
1. Not enough workers
Welding is one of the four key processes in core manufacturing areas like machinery and auto production, along with forging, casting and machining. Companies always need welders, but skilled welders are getting harder to find in the market.
It takes at least 2 to 3 years of systematic training and on-the-job experience to train a skilled welder who can work alone. This process takes long and costs much. Fewer young people want to be welders, so more welders are getting old. The shortage of welders will only get worse every year.
2. High occupational risks
Welding is a typical "high-risk job", with risks everywhere:
Welders have to carry heavy workpieces often;
Sparks from welding may burn the skin, or hurt the ears and eyes;
They are always around loud noise and electromagnetic fields from electric cables and welding equipment;
There is a high risk of safety accidents. People who do this job for a long time are more likely to get occupational diseases like tinnitus, asthma and lung diseases.
Even if all safety rules are followed, welders may still get hurt or need to take sick leave. If one welder stops working, the whole welding production line may stop too, and the company will lose a lot in production.
3. Unstable quality
Manual welding can never guarantee stable quality. When welders get tired after working for a long time, the welds on the workpieces will have obvious differences in smoothness and surface shine.
Besides tiredness, welders can hardly weld two workpieces in exactly the same way. This inconsistent quality is very harmful for companies that want to produce products in a standard way.
4. Production capacity limits
A welder’s output is always limited by their physical ability. When a company gets a big order and the workload doubles, even if welders agree to work overtime, they cannot finish twice the work in 8 hours.
When market demand suddenly goes up, the maximum production capacity of manual welding will show up at once. Companies have to either give up the order, or accept it and then face delivery problems.
The Solution: Welding Robots Fix 90% of Production Problems
Every problem has a solution, and welding robots can solve welding problems.
By automating the welding process, you can fix most of the production troubles:
Welding robots can work 24 hours a day, 7 days a week, easily exceeding the production limit of manual work;
Welding parameters can be controlled precisely, so every workpiece has the same quality from the start;
Robots can take the place of workers in dangerous environments, completely avoiding safety risks, making workshops safer and production more stable.
If you are troubled by problems like not having enough welders, unstable quality or insufficient production capacity, don’t let these problems stop your company’s development. Contact RBTC professional technical team right away.
We will make custom welding robot solutions according to your factory’s situation.
RBTC support a "single workstation start" model, so you don’t need to upgrade the whole production line at once. This fits the budget of small and medium-sized factories, and makes automation really suitable for the production needs of the industry.
