Case Study: Zippertubing Company doubles production and achieves zero defects with Universal Robots UR5

Snappy collaborative robots at Zippertubing Company deliver zero defect rate while doubling production output

Zippertubing Company, a family-owned manufacturer serving automotive and aerospace markets, faced a sharp rise in demand for its thermal wraps while struggling to keep up with a fast, highly repetitive snap-fastening process. With no robotics experience, the team looked for a simple, user-friendly automation solution and chose Universal Robots’ UR5 cobot to help handle the precise insertion of cable jacketing into snap machines.

Universal Robots implemented a UR5-based cobot cell that pick-and-placed fabric through snap-setting machines, used vision inspection to check part quality, and supported safe human-robot collaboration. The result was zero defects, improved part tolerance by 300%, and a 32% labor reduction in those applications, while also enabling lights-out production that could double output and deliver an estimated two-year ROI.

Zippertubing Company

Matt Hesselbacher

Engineering Manager