Modine’s 365 Day Journey Led to Award Winning Cobot Welding Success
Achieving Excellence in Welding Automation
In just one year of partnership with Flextur, Modine's achievements in utilizing cobots in welding automation for increased throughput – by training current staff and investing in technology – earned them the AWS WEMCO 2024 Excellence in Welding Award.
From Idle Robot to Industry Recognition
In less than a year, the team at Modine's Jefferson City plant, in partnership with Flextur, achieved remarkable success by revitalizing an idle collaborative robot (cobot) and integrating it into their high-mix, low-volume production process. Initially, the plant started with a single cobot, and, within this short period, they have expanded to four fully operational cobots. These cobots, including the integration of a 7th axis and a turntable, are among the most advanced on the market. The transformation began in July 2023, with the plant moving from five standard hours per month to consistently achieving over 600 standard hours per month by June 2024. Modine's journey began with welding parts just 1 foot wide, progressing to the successful welding of 8.3-foot-long, watertight tanks. They didn't stop at small parts - they tackled complex welding tasks, including 900-inch linear welds, improving throughput by over 250%.
Breaking Barriers in Welding Throughput
Modine's adoption of cobots for welding automation has had a profound impact on the welding industry. This award-winning achievement showcases the potential of cobots in handling complex welding tasks with innovative station setups for automation welding, setting a benchmark for the industry.
Accelerating welding throughput through automation is a cornerstone of Modine’s 80/20 Lean simplification strategy. Over the past 365 days, our lean initiatives have yielded remarkable results: a three-fold increase in department throughput for most parts and a staggering four-fold boost for select components. It has been fun driving these changes!
Nilesh Tapdiya Lean/CI Manager, Modine, Jefferson City, MO
Training the Workforce of the Future
Furthermore, Modine, in partnership with Flextur, has set an exemplary standard in training and developing their team. Initially, this project started with no automation engineers on staff. Currently, the company has trained over 12 welders to operate cobots independently. This initiative not only maximizes human talent but also addresses the industry's skill gap by equipping welders with automation skills. Modine's approach provides a scalable model for the industry, demonstrating how companies can effectively train their workforce and enhance operational capabilities through successful partnerships with companies like Flextur, that design welding fixtures and quick-change tables for welding automation.
The success of any investment really comes down to how quickly it pays back against the sacrifices made to launch it. The cobots, quick-change tables, and fixtures have rapidly improved our safety, quality and capacity. They have been relatively easy to deploy, and we look for more opportunities to add more throughout our transformation. These projects have been a win all around.
Glenn Zimmerman, Manufacturing Engineering Manager, Modine, Jefferson City, MO
Custom Solutions for Efficiency
Flextur’s mobile toolboards were also deployed throughout the Jefferson City facility.
Designed to support lean initiatives, these products increase efficiency through organization and the elimination of wasted steps and unnecessary clutter. In addition, Flextur provides custom material handling solutions for the safe distribution and storage of in-process materials within the facility.
A Legacy of Innovation
For more than 100 years, Modine has provided commercial, industrial, and vehicular markets with trusted systems and solutions to manage heating and cooling and improve air quality. Their technologies solve mission-critical thermal management challenges while improving air quality, reducing energy and water consumption, lowering harmful emissions, and enabling cleaner running vehicles and environmentally friendly refrigerants. Modine is a global company headquartered in Racine, Wisconsin (U.S.), with operations in North America, South America, Europe, and Asia.
A Model for Industry Transformation
Modine’s leadership in the thermal management industry is underpinned by its relentless pursuit of innovation. The company has pioneered numerous advancements in heat transfer technology, consistently pushing the boundaries of what is possible. Modine’s innovative spirit is exemplified by its integration of collaborative robots (cobots) in welding automation at its Jefferson City plant. This initiative has transformed Modine’s welding operations, significantly increasing efficiency and setting a new standard for the industry. Modine’s Jefferson City Plant has over 60 welders in three shift operations, with a significant percentage of the work force being AWS certified welders.
