Bunorm Maschinenbau, a Swiss company founded in 1965, started with basic welding constructions before transitioning to machine engineering. Today, the company specializes in machining and special purpose machinery construction, with a particular focus on complex and large welded constructions with mechanical processing. They offer the production of small and large individual parts, small series, complete assemblies, and systems.

Four years ago, Bunorm Maschinenbau joined the Swiss Factory Group to strengthen their presence in the Swiss market. The company employs about 100 people across two locations with a total production area of 10,500 sq. m. (113,021 sq. ft.). As a comprehensive welding solution provider, they are committed to the consistent modernization of their machine park.

The challenge: programming diverse complex welds efficiently with quality

With the significant flexibility of their machinery, Bunorm Maschinenbau can handle machine parts ranging from 100 mm to 18,000 mm. However, the necessity to alternate between different products and adjust to fluctuating demand patterns can result in inefficiencies, extended lead times, and heightened operational costs. These are typical production challenges encountered by manufacturing companies in a high-mix, low-volume environment. To ensure high efficiency and quality in their production process, Bunorm Maschinenbau aimed to enhance their robot programming efficiency and transition beyond manual programming.

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau, has been with the company for over a decade. Starting as an apprentice tasked with welding on the production line, he has now become an international welding specialist and the head of non-destructive testing. With 10 years of robot programming experience, he is also in charge of managing Yaskawa welding robots and programming for special projects, such as aviation.

Complex welding capabilities enabled by offline programming

Offline programming (OLP) allows complex individual parts, as well as series parts, to be programmed and optimized in advance on the software outside of the production.

The company can weld constructions up to 20 tons and machine constructions up to 60 tons. They have two welding robots from Yaskawa, both programmed with Visual Components OLP. The first robot Yaskawa YRC1000 can weld workpieces up to 7 m (22 ft) in length, 1.5 m (4.9 ft) in width, and up to 3.5 tons. The second robot Yaskawa DX200 can handle workpieces up to 2.5 m (8.2 ft) in length and 1.5 m (4.9 ft) in width, up to one ton of weight.

OLP can be a valuable tool in projects that involve not only extensive robotic welding, but also partial robotic welding. One example is the production of a machine designed to seal tunnels with foil to prevent water ingress. A major part of this machine was robotically welded with the robot programmed using OLP.

With Visual Components OLP, multi-layer welding seams can be programmed easily, making it possible to handle complex welding tasks. The software also simplifies troubleshooting robot program for reachability and collision issues.

Visual Components has a huge library. The list of post-processors you’re seeing on my screen right now is just what you get for free (included in the license). I believe they have even more based on what I know, but I’m just a customer. I think Visual Components is compatible with every robot brand.

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau

Improving weld quality and production efficiency

Offline programming makes it possible to implement measuring operations very easily, leading to an increase in weld quality. The software enables efficient operation of the welding robot and minimizes downtime.

Even for small batch sizes, such as 15 identical pieces, offline programming proves to be more efficient than manual programming. With online programming, it would take at least two days to program the robot for such a task using the teach pendant. With offline programming, the same program can be completed in half a day, reducing programming time by 75%.

What I will show you is how I post-process the program… you can see that with these 3 statements, I just created 41 lines of program. I could have written 41 lines of code on the controller, but this is my way of showing you how efficient Visual Components OLP is.

Without Visual Components OLP, we wouldn’t consider it to be efficient enough with the robot if we were to program it by hand on the controller.

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau

Getting started with offline programming

If you are a manufacturing production manager considering the adoption of OLP software, D’Angelo recommends testing the software if possible. Visual Components provides the opportunity for potential users to evaluate our software, request a personalized web demo here to get started. He also highlights the excellent support provided by Visual Components, citing his own experience of learning to use the software.

“Vidisha, an engineer from Finland, flew to Switzerland. She measured the machine and the whole jig from the robot. She created the cell for me and simultaneously taught me how to use it during her visit. These three days provided a good enough foundation for me to further improve my skills. Whenever I had a question, I could always reach out to Vidisha via call or email, and she responded very quickly. The support from Visual Components is really, really great.”

D’Angelo Michael, Strategic Welding Solutions Manager at Bunorm Maschinenbau

Bunorm Maschinenbau’s case study showcases how a parts supplier can utilize offline programming to address complex welding projects, achieving substantial gains in efficiency and quality, even within a high-mix, low-volume production setting. With a commitment to innovation and a focus on efficiency and quality, Bunorm Maschinenbau continues to strengthen its standing as a leader in the manufacturing and assembly of complex and large parts in the Swiss market.

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post Mastering complex welding: Bunorm Maschinenbau’s quality and efficiency boost with Visual Components OLP appeared first on Visual Components.

Established in 1970 with a mission to manufacture the world’s best forest machines, Ponsse Plc., a Finnish company, is a global pioneer in the forest machine industry. With a 40,000 sq. m. (430,000 sq. ft.) factory in Vieremä, the company specializes in the sales, service, manufacturing, and technological development of environmentally-friendly cut-to-length forest machines. Ponsse employs over 1,800 people, operates in 40 different countries, and manufactures a wide range of harvesters, forwarders, and other machines. 

With innovation as one of its core values, Ponsse is committed to advancing sustainable forestry through continuous improvement of products, services, and processes for customer success. This has resulted in the creation of modern forest machines and a growing number of satisfied customers. To meet customer demand, Ponsse manufactures around 1,000 machines per year and commissions approximately one new robot station annually.

Boosting productivity with robotic welding and offline programming 

In challenging production environments, welding automation is essential to increase productivity. Recognizing this, Ponsse has always prioritized the improvement of welding processes in its production development. This understanding led them to implement robotic welding more than 15 years ago. Heikki Selkälä, Production Development Manager at Ponsse, shared that their goal is to robotize all basic welding, as part of their broader initiative to automate as many processes as possible, with a particular emphasis on welding.

When Ponsse incorporated robotic welding into their operations, they encountered difficulties because of the complexity and time-consuming nature of robot programming. The programming was carried out online using a teach pendant, requiring the robot to be inactive for a two-week period until the programming was finalized. This pause in operation had significant cost consequences, as it could potentially cause delays in the manufacturing process. 

To address these challenges and significantly reduce robot programming time, Ponsse needed a partner with the expertise and understanding of offline programming. The solution combines the offline programming expertise of Delfoi Robotics, now Visual Components Robotics OLP, with the powerful Visual Components platform. 

Today, 80% of the equipment are welded by robots. Our partner for offline programming of these robots has been Visual Components since the beginning. The cornerstone of our common growth story has been the continuous development of Visual Components software to meet our needs. Their process expertise has developed considerably, and we have always been able to rely on their agile way of working.

Heikki Selkälä, Production Development Manager, Ponsse 

Ponsse sets high standards for its production processes and expects the same level of customer-centric, long-term commitment, and reliability from its partners. Visual Components Robotics OLP, previously known as Delfoi Robotics, has been fulfilling these requirements for over 15 years. 

Enhancing automation utilization for continuous production 

With the help of Visual Components Robotics OLP, despite Ponsse’s highly demanding production processes and complexity of the robot programs, the programs can be completed within one day. The programs consist of Yaskawa robots performing the welding of forest machine frames, including several curved welds and welds within frame structures. 

The benefits of offline programming are realized everyday. As a key benefit, I see that offline programming makes things much faster and easier when robot programming can be done outside of production system without stopping production. Before, we had to make the necessary adjustments during the weekend before the production continued on Monday. Instead of the ten days that programming previously took, now the programming can be completed in just one day.

Asko Haataja, Head of Robotics Team, Ponsse

Improving weld accessibility to maximize productivity

In addition to offline programming, Ponsse uses the robot programming and simulation software to evaluate weld design for practicality, weldability, and accessibility. By testing weld design in conjunction with product development, the manufacturer ensures that the welding process is efficient and can reach difficult areas. This helps maximize the proportion of robotic welding relative to manual welding. 

During online robot teaching, there are scenarios where “hidden spots” in the welded parts are not visible to the operator and therefore require manual welding. However, with offline programming, the operator can view the product in the CAD model, enabling the welding of internal, hidden areas with a robot. This significantly increases the degree of automation and accelerates the entire production lead time by dramatically reducing the need for manual welding.

The customizability and the features of Visual Components Robotics OLP have been excellent for our needs. The visual platform is practical and the code can do things that would otherwise require manual operation. When the need is to weld with multi-axis portals, an ordinary software company could not serve us. Especially in these matters, Visual Components’ flexibility and agility brings us benefits that we value.

Heikki Selkälä, Production Development Manager, Ponsse

Visual Components Robotics OLP is utilized not only when introducing new products but also in refining existing programs, reflecting Ponsse’s commitment to continuous development. 

Streamlining robotic station design and calibration of multi-robot brands  

When planning for new robot cells, Ponsse uses Visual Components from the robotics concept design to ready-to-go robot programs. The design of new robot layouts is an iterative process, during which Ponsse uses Visual Components as a layout design tool. This tool helps define the optimal layout for a specific robot configuration and the products to be manufactured in the robot cell. The all-in-one Visual Components Robotics OLP, being universal and compatible with all robot brands, supports Ponsse’s use of multiple industrial robots from different manufacturers. 

When the design of a new robotic welding station starts, we will model a digital replica of the station with software and test the welding possibilities of the parts. Once the investment decision has been made, I will contact Visual Components and we will continue to complete the planning.

Asko Haataja, Head of Robotics Team, Ponsse

The advanced simulation capabilities of Visual Components Robotics OLP enable accurate validation of robot programs prior to their deployment in production. The final stage of new robotic station implementation, known as commissioning, involves calibration of the designed robot cell for accuracy, ensuring that the programs function accurately for a faster production ramp up. Ponsse has several Yaskawa and ABB robot stations, all of which are programmed offline.

A good example of Visual Components’ agile operations and rapid response is how they developed remote calibration for offline programming during these exceptional circumstances in recent times. In particular, they don’t have to be physically present here at the factory to advise us when the calibration of the robots can be done virtually from anywhere.

Asko Haataja, Head of Robotics Team, Ponsse 

Ponsse’s partnership with Visual Components has resulted in significant time savings, improved productivity and automation utilization, streamlined robotic station planning with faster and easier robot programming. This case study exemplifies how Ponsse, a global leader in forest machines, has harnessed innovation and productivity with Visual Components Robotics OLP to stay ahead of the competition in the industry. 

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post Ponsse is driving forest machine innovation and improving productivity with Visual Components Robotics OLP appeared first on Visual Components.

Berlin Gardens, established in 1988 in the heart of Amish Country, Ohio, began as a humble greenhouse, selling plants and flowers to the local community. This early period instilled a deep understanding of craftsmanship and community values, which would later become the bedrock of their business philosophy.

The transition to manufacturing outdoor furniture marked a significant shift in their business model. Their focus on easily shippable, stylish furniture designs quickly set them apart in the market. Under the leadership of Sam Yoder since 2008, the company has expanded its workforce to 250. The company has evolved to specialize in manufacturing high-quality outdoor poly furniture and backyard structures, employing state-of-the-art machinery alongside time-honored crafting techniques.

Understanding the competitive landscape

In the last 15 years, the poly furniture industry has transformed significantly. What was once a novel concept has now become a competitive and bustling market segment. Berlin Gardens has not only kept pace with this change but has also established itself as a key player.

The company’s unique approach focuses less on external competition and more on internal customer service – prioritizing the well-being and satisfaction of its employees. This philosophy underlines their belief in doing business with integrity, including fulfilling promises such as on-time shipping, which in turn enhances external customer service. Sam Yoder’s vision incorporates a Lean Manufacturing approach, constantly refining processes to balance the pursuit of quality with the need for speedy fabrication.

In line with this pursuit of quality with the need for speedy fabrication, the integration of Visual Components Robotics OLP in Berlin Gardens’ welding of aluminum fixtures marked a significant step in the right direction.

Derrick Yoder, the Aluminum Production Manager at Berlin Gardens, oversaw the transition to more efficient and precise automation in processes like arc welding. The crucial first step in this transition was the initial setup and calibration of the robots, expertly handled by specialists from Mach Machines, Partners of Visual Components based in Ohio, USA. This essential groundwork, complemented by Mach Machines’ comprehensive training on the software, provided Berlin Gardens with a robust base for future utilization of Visual Components Robotics OLP in other processes.

Following this foundational setup, the focus shifted to the advanced functionalities of Visual Components Robotics OLP. The main robot programmer at Berlin Gardens, an Amish worker, found the software exceptionally user-friendly and efficient. With just a couple of clicks, he could program multiple robot paths for the Yaskawa robot cell, all on a single platform. Not only that but the knowledge could be stored in the software for future robot programmers to reuse or optimize.

The biggest difference was the amount of points programmed by simply selecting a joint in the software. And it’s not all simple movements. We have different fixtures where it takes a bit of maneuvering to place the welds, but the software handles them just fine with accuracy. When programming point to point with the pendant before everything was very repetitive – spending hours manually moving the robot. Even then it’s hard to stay consistent with different moves with the robot which can cause inefficiencies on wasted movements. With the software everything can be controlled with the same movements each time.

Derrick Yoder, Aluminum Production Manager at Berlin Gardens

The move from traditional, manual programming to an automated system not only streamlined operations but also represented a significant leap in the company’s technological capabilities and digital transformation. Visual Components Robotics OLP found its critical application in programming welds for aluminum fixtures, essential components of the company’s outdoor furniture. This software enabled the programming of complex weld paths and optimized robot movements, leading to significant efficiency improvements.

The shift from manually programming each point with a pendant to selecting joints through the software reduced repetitive tasks, ensuring consistency and accuracy. This change was not just about saving time; it was about enhancing the quality of each piece of furniture produced, maintaining Berlin Gardens’ reputation for excellence. The feedback from the team has been overwhelmingly positive. Employees have noted the dramatic reduction in programming time and the enhanced consistency in the quality of robotic welds, leading to a more efficient production line and improved job satisfaction.

Quantifying the impact

The impact of Visual Components Robotics OLP on Berlin Gardens’ operations can be quantified by remarkable efficiency gains and cost savings. Programming processes that once took days now take mere minutes. For example, programming a complex fixture that previously required a full 13 hours to get into production can now be completed in under 3 hours. An 80% reduction in programming time! This drastic reduction in programming time has not only led to significant labor savings but has also enhanced the overall operational agility of the company. Looking ahead, Berlin Gardens is enthusiastic about further utilizing Visual Components Robotics OLP in its operations. The company is exploring potential expansions in areas where automation can enhance efficiency even further.

Just for example one of our fixtures would have taken a full 13 hours of programming to be ready for fabrication but with the software we can be up and running within 3 hours. That gives you a small glimpse into the labor saved not to mention the efficiency of how the program then runs.

Derrick Yoder, Aluminum Production Manager at Berlin Gardens

Berlin Gardens’ case study is a compelling example of how a company can successfully integrate modern technology into traditional craftsmanship. By embracing technological innovation and maintaining core values, Berlin Gardens has not only enhanced its operational efficiency but has also solidified its position as a leader in the outdoor furniture industry.

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post Welding innovation and tradition: how Berlin Gardens forges ahead with Visual Components Robotics OLP appeared first on Visual Components.

Since the implementation of Delfoi Robotics (now Visual Components Robotics OLP), our parts are more consistent as well as the repeatability of welding has improved significantly. We have more time improving welding and other systems because of the time saved by not needing to do manual programming and touch ups on the programming. Delfoi Arc has proven to be a very versatile software, our robot systems have seam tracking functionality, Delfoi was able to implement the macros for the seam tracking. With the assistance of Delfoi Robotics’ counterpart Apexiz the commissioning could be done with great precision,

Ferdi Beukes, Mechatronic Engineer at Afrit

Delfoi’s robot offline programming has improved the quality furthermore and streamlined the processes. Time savings have been significant though the software has been in use only a relatively short time.

Our engineers say that manual programming man work hours have been reduced by 80% and programming time reduced by 60%, from two weeks manual to four days offline, and we have increased our output of 8 bins a day to between 16 and 20 bins a day. 

Gerhard van der Walt, Continuous Improvement Manager at Afrit

Examples of improvements:

• Manual programming man work hours reduced by 80%

• Programming time reduced by 60% (from 2 weeks manual to 4 days offline)

• Production lead time improved by 62% for not being required to do manual programming

• Number of parts lost by manual programming reduced from 60 to 0 (each part consists of ±120m of welding)

Commissioning and calibration of this AFRIT’s robotic cell were done by Delfoi Robotics’ partner in India, APEXIZ.

We are sure that the programming time will be further reduced after they get more experienced. Features such as cloning, multi-layer, automatic axes optimization, vision system integration, templates and weld databases allows the users to increase their productivity enormously, especially in big systems such as AFRIT’s. For us it is very important that the user is confident to copy and run the programs created offline without any touch-up and we are able to achieve it using Delfoi Arc

Hari Nidamarthy, the founder of APEXIZ

About AFRIT

AFRIT is one of the most respected and innovative trailer manufacturers in Africa. With more than 50 years of experience in the industry and a product built on a constant drive for optimization and innovation, they remain the number one choice for customers who are looking for a more efficient payload and a high return on investment.

About APEXIZ

APEXIZ offers digital manufacturing solutions such as 3D simulation and robot offline programming. APEXIZ and its partner companies have many years of experience in developing simulation and robot offline programming software.

About Delfoi Robotics

Delfoi Robotics is a pioneer company and trailblazer in offline robot programming worldwide and a world-class expert in production simulation and production scheduling and execution. As of October 2022, Delfoi Robotics is a part of the Visual Components Group.

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We have developed a solution that is able to use the same equipment for many different items and in the fall we will start production with a pilot project. We will work with a robot cell and use the Delfoi Robotics (now Visual Components Robotics OLP) offline programming system

Erik Åstrand, a specialist in welding optimization at Volvo CE

”Jigless” welding

The pilot project will focus on the manufacturing of components for Volvo’s dumpers in Braås. The optimization involves introducing ”jigless” welding in production, i.e. welding is carried out using flexible robots instead of customized jigs or fixtures. Erik mentioned,

In the robot cell, we have a handling robot and a welding robot that build the items together. The handling robot picks up and places the different parts while the welding robot welds them together and then we continue a bit at a time until the item is complete.

Mainly, it is about items up to about 60 kilos, but in the long run, the concept can also be an integral part in the production of major components such as vehicle frames. Maximum manufacturing flexibility also requires the fast creation of programs when the robots weld a new item. There, Delfoi Robotics’ offline programming system plays a key role.

Offline programming

Offline programming means that the robots are programmed in a computer environment without disturbing the process. This reduces the number of production stops and reduces production costs. Delfoi Robotics is the world leader in the field of welding, which made them an obvious choice of supplier. About Delfoi Robotics, Erik concluded,

We wanted the best technical solution and software that is compatible with as many robot brands as possible. Delfoi’s system is very visual and intuitive to program.

The robot cell in Braås will be used for 30 low-volume items in a continuous one-piece flow without any set times. If the pilot project goes well, the plan is to apply the same manufacturing principle to more products and other Volvo CE plants.

The post Volvo construction equipment invests in smart manufacturing in a new pilot project appeared first on Visual Components.

Flexibility is key in small-batch production

HT Laser’s customers are mainly Finnish machine manufacturers, for whom it supplies various products as a subcontractor. Production is mainly in small batches, and the products are always tailor-made to the customer’s needs. In terms of productivity and profitability, this requires a lot of flexibility in production, systematic production planning, and the right systems, equipment, and software.

“The most important thing in subcontracting business is to be able to adjust production to the customer’s needs. Sometimes you have to be able to respond quickly when demand is high, and on the other hand, be able to reduce capacity when demand slows down. Flexibility is the key in this business. Offline programming of robots and Delfoi software (now known as Visual Components Robotics OLP) plays a key role in this,” says Janne Tuominen, Product Development Manager at HT Laser Oy.

Robotization is at the core of development

HT Laser has been using welding robots in production for about twenty years and they are used for welding various products. HT Laser and its subsidiaries use robots from several different manufacturers, such as KUKA, OTC, ABB and Yaskawa. The use of these robots is expected to increase in the future.

“We use robots for welding whenever good accessibility is possible, when the number of welding hours is high, or when the number of pieces to be welded is so large that a person can no longer do it. The benefits of using robots are that they can weld tirelessly and the desired quality is repeatable,” says Janne Tuominen, Product Development Manager at HT Laser Oy, and continues:

“Our goal has always been to increase the automation level of production, and Delfoi Robotics plays a key role in offline programming of robots.”

Offline programming of robots brings many benefits

Offline programming is a production-uninterrupted method of programming robots, where the program for the robot is created on a computer outside of production. Delfoi Robotics’ product family covers software for numerous applications in almost all industrial robot applications and is compatible with all robots, regardless of brand. The Delfoi ARC software effectively utilizes the features of a 3D CAD model of a welded piece and welding information, making the generation of programs fast and error-free.

“The benefits of offline programming are realized in our production every day. The biggest benefit is time-saving as programming can be done without stopping production and expensive machines. Timesaving is also achieved by certain software macros that speed up the programming process. Offline programming also solves the problem if the welded piece is large or located in a place where it is difficult or unsafe to climb”, says Janne Tuominen, and continues:

“Offline programming is also location-independent, and we can program robots from one location to several of our factories. That is why we are investing in offline programming expertise and specialization in cooperation with Delfoi Robotics.”

Investment in automation and offline programming together

Investment in production automation and robotics requires ongoing development work. HT Laser is participating in the national AITOOLS1 development project, which aims to measure and verify the benefits of robotics through research. In the three-year project, machine learning models will be developed that are capable of dynamically adjusting and optimizing the robotic welding process. Delfoi Robotics is also participating in the joint project with VTT, Tampere University, and various companies.

“Our strategy is to continuously increase the level of automation. With regard to robotics and offline programming, I would say that we will strongly invest in and grow this aspect. It is good that we have a knowledgeable partner like Delfoi Robotics, with whom we build this future,” sums up HT Laser Oy’s product development manager, Janne Tuominen.

About Visual Components

Founded in 1999, Visual Components is one of the pioneers of 3D simulation. Visual Components’ 3D simulation helps industrial production companies design, test, optimize, and develop production lines as efficiently as possible. Visual Components Robotics OLP software, along with 3D simulation, form a software solution for digitalizing production systems that significantly reduces downtime, saves production time, and improves robotic programming processes.

Want to learn more about the benefits of offline programming for your business? Contact us today!

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