Selecting the right gun and welding wire also can have a significant bearing on the productivity and profitability of your operation, and should be chosen based on how they perform in conjunction with the rest of the system’s components and parts. Subjected to intense heat, spatter and other elements, the gun must be highly durable in order to avoid maintenance downtime. The gun also should be easily serviceable in order to minimize any downtime for spatter removal, contact tip changeover, and other routine maintenance.

Finally, robotic peripherals, such as nozzle reamers, anti-spatter applicators and wire cutters, should be factored into your automation effort. These devices can improve uptime and welding performance.

6. What else do I need to consider?
Predicting your company’s automated welding needs in the years ahead will help you determine the type of system you need. If you have a part that lends itself easily to a fixed automation system, for example, but you aren’t confident that you will be making that part three years from now, a robotic system might be the better choice. It can be reprogrammed and retooled to accommodate your needs in the future.

7. Who should I partner with?
Your automation partner, whether it’s your welding supplies distributor, a robotic systems integrator, an equipment manufacturer or an independent consultant, should be available with support and service throughout the transition to an automated welding system —not just until you install the robot. Further, most reputable robot manufacturers provide at least a weeklong training course, as well as 24-hour support hotlines and field service technicians who can make on-site repairs and/or consultations.

The popularity of automated welding operations is increasing thanks to their welding capabilities and return on investment. If you have a repeatable part, efficient material flow, and a desire to increase your company’s productivity, you should at least be looking into automation. You also should assume that your competition is looking into automation, too.

The first step toward determining if automation is right for you will be to contact a trusted expert who can conduct an on-site analysis of your specific circumstances, recommend the appropriate equipment and configurations, and calculate the payback you can expect.

Kevin Summers is a business development manager with Miller Electric Mfg. Co. Randy Stevens is the director of business development with Tregaskiss.