Towbar production line optimisation utilising cobot welding (Final summary report).

The project aimed to explore the feasibility and benefits of adopting collaborative robotic welding technology to enhance productivity, improve product quality, and prepare for future business growth. The project took a phase-based approach, with each phase having a distinct focus with targeted outcomes. The first phase, “Explore & Define”, was built upon consultations and on-site assessments to understand current manufacturing processes. The second phase, “Develop & Test”, involved technical development, involving five products for testing. Preliminary simulation work was done to investigate how a collaborative robot welding solution could be used on these models, and then an optimised welding jig was designed. The third and final phase, “Delivery”, focused on quantifying production gains, scenario evaluation, cost estimation, welder feedback, and human factors and ergonomics. Two future-state scenarios were developed: (1) full welding with a cobot, and (2) segmented welding using modular sub-assemblies. Job redesign and change management strategies were proposed to support a smooth integration of the technology into the existing workforce. The findings of the project can be applied to develop business capability and position the business for enhanced competitiveness in local and international markets.