Determination of Minimum Batch Size for the Implementation of a Robotic Welding Cell in an Agricultural Machinery Industry

Abstract

The use of robotic welding cells has been steadily increasing, and the agricultural machinery industry is no exception. However, compared to manual welding, robotic cells generally require longer setup times due to the need for fixture replacement and positioning. Combined with the higher hourly cost, this makes it necessary to establish a minimum batch size to dilute setup costs. This study aims to determine the minimum batch size required to make the use of a robotic welding cell feasible in comparison with manual welding. The calculation of the minimum batch size considers process-related costs such as consumables, depreciation, maintenance, and labor—being one of the most significant factors—among others. These data were collected through consultations with various departments of the company, in addition to direct monitoring of the welding process. Based on the collected data, it was found that the hourly cost of robotic welding is approximately 85% higher than that of manual welding.