Abstract
A comparative study of robotic and manual welding in a low volume high mix manufacturing environment focusing on a truck body part named the lift ring to see if there is a benefit of incorporating robotic welding into the production line. By utilizing predetermined time studies such as Methods Time Measurement 1(MTM-1) and Maynard’s Operation Sequence Technique (MOST) in conjunction with normal time and motion study to see which method of time study can be used to extrapolate the times of production for higher number of parts. MTM-1 and MOST were used for a detailed time and motion analysis which were then used to evaluate the efficiency and cost implications and feasibility of incorporating a co-bot welder to execute the tasks of an experienced human welder. Necessity to do the cost analysis and comparison of the co-bot is understanding of the additional cost related to robotic welding such as the fixture costs which include the design cost and fabrication cost, the programming costs, and the common welding costs. The MTM-1, MOST and normal time study was performed, and it was found that MTM-1 is closer to actual in the case of Manual welding, and MOST is closer to the actual time in case of Robotic welding. With the average welding process times used for the cost analysis, the robotic welding breaks even in less than 16 days with the daily working hours being 6. If the robotic welding process is optimized by 5%, the break-even will be in less than 10 days, and if it is optimized by 10% , the break-even will be less than a week.
Advisor
Kuldeep Agarwal
Committee Member
Shaheen Ahmed
Committee Member
Pawan Bhandari
Date of Degree
2024
Language
english
Document Type
Thesis
Degree
Master of Science (MS)
Program of Study
Master of Science
Department
Electrical and Computer Engineering and Technology
College
Science, Engineering and Technology
Recommended Citation
Pothamsetti, Pothamsetti. (2024). Comparative Study of Robotic and Manual Welding in A Low Volume-High Mix Manufacturing Environment: Case Study of Lift Ring [Master’s thesis, Minnesota State University, Mankato]. Cornerstone: A Collection of Scholarly and Creative Works for Minnesota State University, Mankato. https://cornerstone.lib.mnsu.edu/etds/1429/
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