Collaborative Robots Deliver 40% Growth and Round the Clock Manufacturing at New Engineering Works
01 the short story
In an effort to keep up with the market, automotive component manufacturer New Engineering Works deployed their first collaborative robot for CNC machine tending in 2016. The manufacturer installed 6 cobots within 18 months and has seen remarkable results, realizing a 40% growth rate and the ability to manufacture 24x7. The cobots have been seamlessly included in New Engineering Works’ production processes, leading to cost reduction and increase in productivity and efficiency.
02 the challenge
New Engineering Works experienced a continuous increase in demand for hydraulic, pneumatic and engine components for commercial vehicles and realized the need to automate repetitive production tasks. The company, however, had limited space and did not want large machines with limited output occupying their shop floor. New Engineering Works was looking for an agile, automation solution that would facilitate the addition of a third 8-hour shift, thereby enabling them to manufacture round the clock.
Video — 6 UR10 Robots, New Engineering Works, Jamshedpur, Jharkhand, India
03 the solution
New Engineering Works installed their first cobot in 2016 and has purchased 6 cobots within a span of 18 months. The company has a small and large components division, with collaborative robots being perfect for the small components division.
Each of the cobots fit perfectly between 2 CNC machines, occupying limited space on the shop floor while facilitating the tending of 12 CNC machines at a time. They are as easy as using a smartphone – hassle-free, and easy to program and set up. The workers have learnt to operate UR cobots with no prior training.
New Engineering Works has seen a 40% growth in production since deployment of cobots in their manufacturing plant. The manufacturer is now able to run 24x7, thanks to cobots enabling a third 8-hour shift, thereby skyrocketing their productivity. The cobots work side-by-side with humans on the shop floor, enabling safe and efficient production. The installation of cobots has led to automation of processes and reduced the cost per component.
“Investing in cobots does not mean I am letting go of my workforce – rather, I am training them to deliver more meaningful work like quality checks, handle Coordinate Measuring Machines (CMMs), and inspection,” said Managing Partner at New Engineering Works, Binod Kumar Agarwal, who can now explore more business opportunities. He encourages more SMEs to include cobots in their manufacturing processes: “Cobots opens up a lot more opportunities, they are affordable for the small-scale industry and deliver a great ROI.”
Women working alongside with Collaborative Robot UR10, cobots at New Engineering Works, India
Empowering people on the shop floor at New Engineering Works, India
Easy and safe to use on the shop floor at New Engineering Works, India
Empowering women on the shop floor at New Engineering Works, India
A cobot with its co-workers at New Engineering Works, India
04 The Product
New Engineering Works is an SME that was started in 1996. It has been in the manufacturing of hydraulic, pneumatic, engine and brake components for commercial vehicles. Aside from numerous medium-scale companies, New Engineering Works also manufactures components for some of India’s largest automotive giants, including Tata Motors, Ashok Leyland, and Brakes India.
- Land is especially valuable to the Indian SME, and cobots function even with space constraints
- Growth of 40%
- Reduced cost per component
- Allows for workers to focus on more skilled work, with no loss of jobs
- Cobot(s) Deployed: 6 UR10s
- Flexible and space-saving, with no fencing requirements
- Quick ROI, even for an SME
- Plug and play
- Encourages job satisfaction and higher skilled labor as workers are now taught more meaningful tasks
- Machine Tending
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Cost-effective, safe and flexible collaborative robots - or cobots- are making automation easier than ever, even for the small and mid-sizes companies.