Case Study: Blue Star Limited achieves zero quality rejects with Universal Robots UR10 cobots

Collaborative Robots Pave the Path to Zero Quality Rejections

Blue Star Limited, one of India’s leading manufacturers of air conditioning and commercial refrigeration products, faced quality rejections at its Wada plant in Maharashtra because the manual copper tube expansion process was repetitive, physically demanding, and prone to fatigue-related errors. Universal Robots helped Blue Star address this challenge with UR10 cobots for copper tube expansion.

Universal Robots implemented UR10 cobots integrated with vision and AI to detect tube positions, guide the robot accurately, and automate sealant dispensing, drilling, and tool cleaning/lubrication cycles. The result was near-zero quality rejection, elimination of mental and physical stress for operators, and a 10% increase in productivity, while also allowing employees to focus on more meaningful tasks.

Blue Star Limited

Dharmesh Kapadia

General Manager, Manufacturing Engineering