Case Study: Wilson Bohannan triples padlock production with FANUC robots

Wilson Bohannan triples padlock production with FANUC

Wilson Bohannan, a 165-year-old American padlock manufacturer, faced challenges with a tedious and ergonomically difficult manual polishing process, high employee turnover, and dangerous equipment. Their outdated robotic system could not meet growing customer demand. To stay competitive and maintain their reputation for quality, they partnered with vendor FANUC America Corporation and system integrator Acme Manufacturing for an automation solution.

The solution implemented by FANUC and Acme Manufacturing used two high-speed, high-precision FANUC M-10 series robots with innovative tooling to handle 18 different padlock styles. This compact system fit within the existing facility's footprint. The results were transformative: production more than doubled from 1,500-1,800 locks per shift to over 5,000. This provided a consistent, high-quality finish, reduced downtime, improved safety, and allowed employees to transition to higher-value roles.

Wilson Bohannan