Case Studies Industrial

Sep 18, 2015 —

A1 Towing Ltd , a leading manufacturer and supplier of aftermarket Towbar systems recently invested in a Panasonic TAWERS robot welding system

A1 Towing, source Panasonic

September 2015

Mark Terry the CEO of A1 Towing Ltd, selected the single source solution from Panasonic after undertaking suitability evaluations including detailed welding tests. Once satisfied that the robot welder would provide dramatically improved production efficiency with greatly reduced spatter levels and improved weld quality, it then became necessary to develop the system concept to overcome the primary obstacles in the business to using automated welding.

Mark Terry’s overview is “Our production schedules are based upon customer demands with the ability to respond quickly to individual requests, as such we have a low volume batch manufacturing system with a product range of hundreds of variants, with additional new products being added continuously during the year.” The combination of these three requirements traditionally makes the use of automated robot equipment difficult to implement efficiently. Panasonic has succeeded by an innovative system design, which allows a fast and precise applications change to meet the requirements for the production concept of A1 Towing. The Panasonic PerformArc welding cell was equipped with a TM-1400 robot. Two independent established workstations ensure the efficient, speedy loading and unloading of components. With two high-speed roll-up doors, this process is also supported.

The system was installed in January 2015 and after just a few months the robot is now a very important part of our manufacturing process. “We have successfully migrated 45% of our production onto the robot cell” says Mark Terry and adds furthermore that compared to a typically manual welding cycle which takes over 20 minutes could be reduced to a 5 minutes robot cycle.

“Our role is to find solutions to our customers welding problems! We offer a comprehensive range of cost effective solutions that can be matched to the exact requirements of our clients.” says John Hopper, UK Sales Director for Panasonic Robot & Welding. “By working with Mark and the team at A1Towing we were able to provide a complete flexible package that best suited their production requirements and existing skills, providing a fully integrated package of hardware, training and after sales support. Our team is focused on supporting them in the future to ensure they optimize their investment for the long term.”

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