We opted for a FANUC ARC Mate 100iD / 8L with 3 auxiliary axes , because not only does this model deliver fantastic performance , but it also integrated nicely with the FANUC CNC that was already being used at the facility .
“ It also became clear that having an internationally recognisable name like FANUC would be of benefit to the wider business . FANUC ’ s reputation proceeds itself and from CEL ’ s point of view it ’ s great to be able to say to their clients that they have a FANUC machine . There ’ s an element of assured familiarity there . It also helped that CEL ’ s CNC Turret Punching machine is programmed with a FANUC controller , so they had some familiarity with FANUC ’ s industry leading control units .”
EMPLOYEE ENGAGEMENT One of the most commonly cited concerns with introducing automation is the effect it will have on existing employees . There is an unfounded fear that robots will replace jobs , and as Troy explains , this is something that needs to be addressed from the very beginning :
“ Nothing determines a business ’ s success more than its team . It ’ s a cliché but it ’ s true , and we were determined to ensure our staff , our fabricators , our people in offices and the factory were on-board with the improvements that would be brought about by automation . Very early on in the procurement process we talked openly about the benefits during our ‘ All-Hands ’ meetings , and offered training opportunities for our staff to learn about robotics .
“ We got amazing engagement with this , with more time for training as the robot undertook the laborious , time-consuming
Nothing determines a business ’ s success more than its team .
and repetitive tasks . We have developed and trained one of our best welders to lead the robotic programming , and he is doing a brilliant job . Furthermore , many of our other fabricators are learning more advanced welding techniques to go beyond what the robot can do , including more TIG welding of aluminium and stainless steel .”
CEL ’ s focus on investing in its staff has had a significant impact on Contracts Engineering ’ s workforce . Employment has grown + 50 % since 2012 , and average pay is up 20 % on top of a bi-annual company profit share . Job satisfaction is also high , with a low staff turnover of 5-10 % per year , compared with a UK manufacturing average of over 25 %.
GETTING RESULTS Crucially , this culture of openness has ensured the ARC Mate 100iD / 8L has slotted seamlessly into the facility , and by September , just three months after delivery , it was operating at full production capacity . Productivity has doubled , with weld time cut by as much as 60-70 %. This has ensured Contracts Engineering has been able to keep pace with its key bicycle rack client ’ s orders .
Troy continues : “ Without automation , we may have been in the position where we would have had to turn away work , just because we couldn ’ t keep up with demand through manual welding alone . Now , we ’ re able to deliver to existing clients , while also actively seeking out work which requires more advanced welding applications , thanks to our increasingly skilled employees .
“ Aside from the tangible producitivty gains , we ’ ve found that automation has also facilitated greater integration of some of our departments . Engineers who are doing the CAD work are now working closely with the machine operators , which helps to bring the whole process closer together . By the end of 2021 we plan to have our 3D CAD designed integrated with robotic programming so we can do it offline ”
LOOKING AHEAD In spite of the difficult circumstances of the past year , Contracts Engineering has managed to increase its client base . Working with the knowledge that the ARC Mate 100iD / 8L would see a return on investment from the cycle parking project alone , it has allowed Troy to pursue further business with full confidence , including engaging with the other clients that had robotic requirements .
He concludes : “ Investing in robotic automation during a pandemic could be seen as risky , but open and frank conversations with Cyber-Weld Ltd helped to minimise the fear factor that was associated with it . From a business point of view , it ’ s meant an increase in operational capacity that has enabled us to generate more business , and offer our existing clients even greater support .
“ Most importantly , we ’ re delighted with the engagement we ’ ve seen from our staff . It ’ s a perfect example of how automation can enhance job roles , equipping employees with new skills that diversify their working day and ensure we ’ re all pulling in the same direction .”
For more information , please visit : www . fanuc . eu / uk / en , www . contractsengineering . com and www . cyberweld . co . uk
Issue 51 PECM 49