All Graduate Theses, Dissertations, and Other Capstone Projects

Comparative Study of Robotic and Manual Welding in A Low Volume-High Mix Manufacturing Environment: Case Study of Cross Head

Niloufer Sarah, Minnesota State University, Mankato

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 Cross head 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 actual welding 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 actual welding 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 5 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 2 days, and if it is optimized by 10%, the break-even will be less than a day.

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

Manufacturing Engineering Technology

Department

Automotive and Manufacturing Engineering Technology

College

Science, Engineering and Technology

Recommended Citation

Sarah, Niloufer. (2024). Comparative Study of Robotic and Manual Welding in A Low Volume-High Mix Manufacturing Environment: Case Study of Cross Head [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/1461/

Niloufer Sarah Thesis.xlsx (243 kB)