In a significant move towards enhancing workflow and production, RCR has recently embraced automation by investing in robotic welder arm technology. This cutting-edge technology is part of an ongoing effort to streamline operations and deliver superior results for clients.
The role of robotics in RCR's evolution
Mark Hayward, RCR’s Operations Manager, has been at the helm of this transformative journey. RCR has integrated robotics into their manufacturing processes, fully leveraging the potential of this technology.
“My task is to look at how we can do things differently and more efficiently,” Hayward explains. “Robotics and automation are fairly new directions for us, but we are already seeing significant benefits.”
The recent addition of a robotic welder arm in RCR’s Bunbury workshop exemplifies this commitment to innovation. This technology promises faster results, enhanced safety, and reduced wastage. Welding robots, though not entirely new, remain an untapped resource for many businesses in the sector. These robots are programmed to perform precise welding tasks autonomously, significantly boosting efficiency and consistency.
Benefits of automation
The robotic welder arm has been a game-changer for RCR. It ensures that welded items are produced consistently, without compromising on quality. The technology has reduced lifting requirements by up to 75% and minimised manual handling, allowing RCR to reallocate resources to tasks that cannot be automated.
“Using the manual processes, we could produce eight items in a day. Now, we’ve managed to reduce the cycle time from an hour per item down to about 20 minutes per item. On a really good day, we can get it to 15 minutes,” says Hayward.
The implementation of this technology came at a challenging time for RCR, amidst labor shortages and an increasing workload. Despite these hurdles, the robotic welder arm has quadrupled the production rate, while maintaining high standards of quality and consistency. Additionally, it has significantly reduced incidents, injuries, and risks associated with manual handling, highlighting the safety benefits of automation.
Sustainable and efficient practices
RCR’s commitment to sustainability is evident in its adoption of LEAN manufacturing principles. By focusing on minimising waste without compromising productivity, the company has fostered more environmentally friendly practices. The robotic welders have reduced environmental damage and protected staff from hot sparks and other risks associated with manual handling. Operators are now removed from fumes and arc radiation hazards, further enhancing workplace safety.
Driving workplace efficiency with apprenticeships
The push for greater technology adoption has also paved the way for an innovative apprenticeship program at RCR. Apprentices are being trained to program and operate the robotic welder arm, ensuring a steady stream of skilled workers. This program has nearly quadrupled the number of apprentices since 2020, with 20 new apprentices joining last year alone. The apprentices are rotated across different trades within the business, gaining diverse experiences and upskilling continuously.
