When Craftsmanship and Automation Join Forces

Flexibility for complex processes

High production demands coupled with a shortage of skilled workers call literally for automation. What should such a solution look like that can be easily integrated into existing workflows and still leaves enough room for individual precision work? Schuster Bestuhlungen from Kaiserslautern, Germany, was at exactly this point – and found a solution that is accepted by all employees.

The family-run company has been manufacturing lecture hall and auditorium seating for public institutions and educational establishments throughout Germany for over 30 years. Its strength lies in its ability to carry out complete projects. These range from planning to individual precision work in wood and metal and upholstery to on-site assembly. This requires flexibility, but also makes the processes very complex. If there is a problem at one point, it affects the entire workflow.

The construction of lecture hall stands and stage substructures requires several welding steps. Up to three welding specialists previously worked on each component. In addition, individual components required different templates and tools, which often had to be changed over. The manpower required was immense. So was the risk, as the welded components showed slight deviations. Rework was necessary even during assembly. Long welding sessions in forced positions and exposure to welding fumes made it difficult to find young welding specialists who were willing to accept such conditions.

Green light for load reduction and process reliability

Schuster Bestuhlungen realized more than 10 years ago just how much automation could simplify processes. At that time, the company invested in a CNC woodworking center, which simplified processes and increased efficiency. This positive experience should now also be applied to welding work, relieving the strain on welding specialists and boosting productivity.

Various automation options were considered. However, the company's main requirement was to retain the flexibility needed for customized projects and to be able to cover a wide range of applications. It was also important that non-specialists be able to operate the automation solution. The team opted for the iBOTone welding cobot from Abicor Binzel and had the opportunity to test it for two months.