Automation vs mechanization, when it comes to welding, is a difficult question. Both are valuable tools for improving the efficiency and productivity of welding operations. However, there are some key differences between the two processes, including the level of automation, the production capacity, the safety, and the investment cost.
So, to take a good decision regarding this, we need to study both in detail. After that, you need to compare that with your own circumstances. So, let’s start by defining both ways to apply welding.
What is welding automation?
Welding automation is the use of robots, machines, technology, and other automated systems to perform welding operations, with almost no intervention from operators. This can be used to automate all aspects of the welding process, from loading and unloading parts to positioning parts to welding them together. The purpose is to enhance quality, productivity, and efficiency.
We recommend you read the article “Welding automation: A complete guide” for a complete view on this topic.
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What is welding mechanization?
Mechanized welding refers to a way of applying welding in which a device performs the task with partial intervention from an operator, in response to visual observation of the welding. The mechanical device used holds the electrode, wire or workpiece while the welding is performed. The intervention from the operator is constant and required after every cycle.
Welding carriages, plate bevelers, and orbital welding equipment can be counted as part of this concept.
We recommend you read the article “Mechanized welding: A complete guide” for a complete view on this topic.
So, the basic difference between automation and mechanization is the degree of involvement from human operators in the actual welding. This being said, let’s start with the comparison regarding setup timing, production capability, safety, and investment.
Automation vs Mechanization: Setup timing
Welding automation and mechanization are both methods of improving the efficiency and productivity of welding operations. However, there are some key differences between the two processes, including the setup time.
Welding automation involves the use of robots and other machines to perform all aspects of the welding process, from loading and unloading the parts to be welded to positioning the parts to welding them together. This can lead to significant reductions in setup time, as the robot or machine can be programmed to perform the same task repeatedly with minimal human intervention.
To illustrate this, let’s say that your production line allows for no need to change the task the welding robot is going to perform during the whole day. In that case, at the beginning of the shift what you need to make sure is that you set up correctly the task you want the robot to perform, and the operator in place will oversee supplying materials and consumables. Your setup time will only be the minutes you spend programming the robot at the beginning of the shift.
Welding mechanization involves the use of machines to automate specific tasks in the welding process, such as moving the welding torch or positioning the parts. This can also lead to some reductions in setup time, but not to the same extent as welding automation.
Let’s bring up an example. Let’s say that you use a welding carriage to weld long beams in tanks fabrication, and that is all you are going to do with the device during the whole shift. You need to set up the carriage at the beginning, with the parameters for that job. But besides that, you need to set in place the tracks needed for the carriage to move forward. So, for every welding beam that is going to be made, the carriage is going to need some set up time.
Setup timing: Automation
In general, welding automation has a lower setup time than welding mechanization, so we have a winner in this point. This is because welding automation can be programmed to perform all aspects of the welding process, while welding mechanization typically only automates specific short tasks.
Automation vs Mechanization: Production capacity
Welding automation and welding mechanization can both increase production capacity, but welding automation typically offers the greater increase.
Welding automation allows for continuous welding, with minimal downtime for setup and operator intervention.
A welding robot doesn’t get tired, distracted or fatigued. As long as it has materials in place and consumables, it will keep welding. Also, the high quality of welding automation results in very few to no rework.
As an example, if welding one workpiece takes 5 minutes, after 8 hours of continuous work you will have 96 pieces. Let’s put a pin on this and compare it later with the example of mechanization.
Welding mechanization is fast in performing the welding process, but it requires intervention for such as moving the welding torch or positioning the parts. This can also increase production capacity, but not to the same extent as welding automation.
Following up with the example, let’s say that the welding process takes the same 5 minutes, but, since the operator needs to intervene every time, let’s add 1 minute to that, which seems not too much time. This would mean that in a period of 8 hours you will be able to produce 80 pieces.
If your company works 3 shifts daily, every single day of the week, in an average month you will produce 8,640 pieces with automation, but 7,200 with mechanization. If the value of each piece is $100, you could sell $864,000 with automation, while only selling $720,000 with mechanization. As you can see there is a big difference in automation vs mechanization regarding production capabilities.
Production capacity: Automation
In general, welding automation offers a higher production capacity than welding mechanization. This is because welding automation can perform all aspects of the welding process continuously, while welding mechanization typically only automates specific tasks.
So far, we are 2-0 in favor of automation, but let’s keep developing this matter.
Automation vs Mechanization: Safety
Mechanized and automated welding can both improve the safety of welding operations by reducing the operator’s exposure to hazards associated with welding, such as fumes, heat, and radiation. However, welding automation typically offers a greater improvement in safety, as it can eliminate the operator’s need to be present in the welding area altogether.
In general, welding automation offers a higher level of safety than welding mechanization. This is because welding automation can eliminate the operator’s need to be present in the welding area, while welding mechanization typically only reduces the operator’s exposure to hazards.
So, this means that now we are 3-0 in favor of welding automation. But still there is a key point to consider.
Automation vs Mechanization: Investment
Welding automation and welding mechanization both require a significant investment, but welding automation typically requires a higher initial investment. This is because welding automation systems are more complex and require more sophisticated hardware and software.
For example, while a basic welding carriage can cost something around $3,000 to 5,000, the price of a basic welding robot can be $20,000 to $25,000. Additionally, to that you need to consider the JIG, which is the device that is going to upload and position the workpieces to be welded, as well as removing them from the area.
In general, welding automation requires a higher initial investment than welding mechanization. However, the long-term cost savings from welding automation can be significant, due to increased productivity, improved quality, and reduced labor costs.
So, while both systems have different ROI periods, we need to recognize that at this point mechanization won, so this match finished 3-1.
Automation vs Mechanization: Other factors to consider
Beside the forementioned, here are some additional factors to consider when choosing between automation vs mechanization:
The complexity of the welding task: More complex welding tasks will typically require a higher level of automation.
The desired quality level: If you require a very high level of quality, then welding automation may be the better choice, as it can produce more consistent and repeatable welds.
The availability of skilled labor: If you have difficulty finding skilled welders, then welding automation may be the better choice, as it can reduce your reliance on skilled labor.
Your long-term goals: If you are planning to grow your business in the future, then welding automation may be the better choice, as it can help you to scale your production capacity more easily.
Automation vs Mechanization: Last thoughts
The best welding process for your application will depend on a variety of factors, including the type of welding process, the level of automation required, the desired production capacity, the safety requirement, and the budget.
The deciding factors are: if you are looking for the highest level of autonomy, production capacity, and safety, then welding automation is the better choice. However, if you have a more limited budget, then welding mechanization may be a better option.
Ultimately, the decision of whether to choose welding automation or welding mechanization will depend on your specific needs and requirements.
Now, you don’t have to figure it all out on your own. We have been advising companies for decades on how to implement welding automation or mechanization. Contact us whenever possible and we’ll be happy to help you too.
