Programmers behind the production
The fixturing of the robotic systems are critical to the success of each product. They must be accurately designed and programmed to hold critical tolerances; easy to load and unload; designed to hold as many parts as possible; and robust enough to withstand the rigors of consistent use. G&W management relies on its team of specially trained programmers to oversee this crucial element of its robotic operations.

Some members include journeyman welders, while others on the team are experts in automation and know how to run the equipment and program it for maximum weld quality, consistency and speed. Those who were not welders by trade have received welding training so that they can know how to recognize good weld penetration and quality.

Two senior operators oversee the operation and programming of all the cells, but all of those on the robotics team have been trained in the proper operation of the units. All operators attend Lincoln’s Welding School, and the senior operators have also attended Lincoln’s Advanced Training program. The team also participates in regular internal training sessions on welding and weld inspection.

""Our programmers’ backgrounds are varied. When we identify who is best suited to run the robots, we realize they might require additional welding training, or they might need training on the equipment and how to run it," Keehn says. "It requires both skills. You don’t necessarily need to have a welding background, but you do need to have a strong knowledge of good welding and programming and know how to manage those cells to deliver a superior quality weld. We’re not just welding sheet metal. Our work involves many different aspects of welding."

This move towards automation was driven by the desire for higher volume weldments and also the desire to increase value-added capabilities as a competitive advantage, Sagraves notes. He stresses that robotics isn’t just for large fabricators.

Making the move to robotics has helped reshape and strengthen G&W Products’ business, despite the challenges of a struggling economy. Johns says he believes adding robotic welding to the shop’s service offerings was one of the best strategic moves the company management has made. He says they only wish they had integrated them sooner.

"Integrating automation into our operations reflects our company’s overall direction and growth plans," Johns says. "Efficiency is an overall theme. We’re looking to become leaner, more flexible and more competitive. Robotic welding fits perfectly into this plan. Robotics is more than a fad in this industry. It’s an ingredient to a plan to stand above the competition."
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