Case Study: T&W Stamping achieves 40% efficiency increase with Universal Robots cobots

Universal Robots Automates Challenging Resistive Welding Task, Delivering 40% Efficiency Increase

T&W Stamping, a contract manufacturer in Ohio’s heavy-duty truck market, needed a way to automate one of its most labor-intensive processes: tending resistive welders for powertrain brackets. The challenge was fitting automation into an existing layout while dealing with electromagnetic pulses that can disrupt electronics, making the application difficult for robotics.

Universal Robots, working through integrator Crum Manufacturing, implemented a UR5 collaborative robot with vision guidance and custom end-of-arm tooling to pick, position, and move parts between two resistive welders. The solution increased efficiency by about 40%, reduced the cell to one operator, and delivered payback in less than four months, with T&W Stamping reporting consistent output, no downtime, and 100% product quality.

T&W Stamping

Craig Sivak

Executive Vice President & General Manager