For seven years E-Profiil AS and Pemamek Ltd. have teamed up to power E-Profiil’s production
The high-flying collaboration has resulted efficient solutions and expanded opportunities in production.
Challenge: In the latest project the challenge was to automate welding of geometrically challenging parts.
Solution: PEMA Robotic Station with a large 2-axis positioner and tailored 8 m diameter positioner.
Benefit: The manufacturing process is now 5 times faster enabling 24 / 7 operating, which was before impossible.
PEMA “State-of-the-art” Technology
Long partnership
E- Profiil AS, located in Tallinn, Estonia, is a contract manufacturer of complex, big and heavy steel structures. Since 1997 the company has provided equipment and solutions for offshore, energy process and machine- building industry. As the business has rapidly expanded, the future plan is to further develop production and grow through investing in new technologies.
The history of E-Profiil and Pemamek’s collaboration goes back to 2009 when the two companies banded together to find a solution for E-Profiil’s need to acquire a welding positioner. After a well ran project, foundations for strong partnership were established.
In 2012, the solid cooperation led to commissioning of PEMA Column & Boom SAW Welding station including two positioners. Additionally, in 2014 E-Profiil invested in PEMA Robotic Station and a year later, in 2015, in eight pieces of rollerbeds.
Throughout the seven-year partnership, convenient locations and mutual understanding have been crucial factors for smooth collaboration.
Throughout the seven-year partnership, convenient locations and mutual understanding have been crucial factors for smooth collaboration.
– Pemamek is our partner in welding automation and we have positioners and column and booms of their production. Pemamek is experienced in integration of robotic system solution and not only in GMAW welding but also other welding methods. Also, they are our neighbor, which makes our cooperation easier and faster, says E-Profiil’s Business Development Manager, Martin Mehilane.
To increase efficiency in steel structure fabrication and to maintain precise quality in their production, E-Profiil decided to invest in automation. After visiting convincing reference sites and being assured by the previous cooperation, E-Profiil chose to join forces with Pemamek.
– We had good proposals from multiple technology companies which met our expectations, but we decided to go with Pema due to their good references, solid solutions and our previous good cooperation experience, Martin Mehilane notes.
We had good proposals from multiple technology companies which met our expectations, but we decided to go with PEMA due to their good references, solid solutions and our previous good cooperation.
Expected ROI with PEMA Robotic Station
Due to the one-off product nature of the company and “One stop shop”- philosophy, the requirements for the machine were pinpoint accurate, such as off-line- programming module, versatility, traceability, yet still it is affordable. In the core of E-Profiil’s commission was that the solution is able to weld different types of products and to shift from one product to another rapidly with little effort.
– Many challenges, related to automation and production, were solved thanks to great cooperation of Pemamek and E-Profiil teams, says Mehilane.
The obotic station, designed in collaboration with the teams from E- Profiil and Pemamek, has already showed evidence of enhancing several business functions, such as providing accurate quality and reaching the expected level of return on investment. When compared to manual methods, the station provides five times faster production. To boost manufacturing, E- Profiil utilizes PEMA Off-line programming, which enables full control and visualization on customer projects.
– As a basic rule – one robot operator replaces four to five manual welders. This new technology allows us to enter into 24/7 operation with welding. We have been able to reduce the self-cost of welding, reached expected level of ROI and but also improved our fabrication quality, tells Mehilane.
Significant Benefits from Transitioning to Automated Welding
Making the decision of replacing manual welding with automated and robotized way of working is never an easy task. There are several aspects to consider, such as which solution has the best return on investment or how much other changes must be done in the production chain. The transition might include several challenging steps.
– There are many challenges when executing such a complex task. We have spent time on solving topics, such as finding the right people for robot operation and programming, preparation of materials and fit-up suitable for robot welding, finding right welding parameters, elimination of errors in system, says Mehilane.
According to Mehilane, in order to make transition smooth and to be able to make the most out of new technologies, a profound planning and good professional team are main keys to make the transition smooth.
– It is very important to make good planning and allocate sufficient amount of time for development project, build up good development team. Don’t be afraid to robotize and have the courage to make this step, concludes Mehilane.
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