{"id":860,"date":"2022-04-30T12:45:45","date_gmt":"2022-04-30T12:45:45","guid":{"rendered":"https:\/\/www.astor.com.pl\/en\/?p=860"},"modified":"2025-07-02T13:54:49","modified_gmt":"2025-07-02T13:54:49","slug":"wisniowski-digital-individualisation-in-the-factory-of-the-future","status":"publish","type":"post","link":"https:\/\/www.astor.com.pl\/en\/case-studies\/wisniowski-digital-individualisation-in-the-factory-of-the-future\/","title":{"rendered":"WI\u015aNIOWSKI \u2013 digital individualisation in the factory of the future"},"content":{"rendered":"
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Goals: \n\u2022 Improved production efficiency \n\u2022 Improved quality of the production processes \n\u2022 Enhanced safety for operators<\/p>\n
Benefits: \n\u2022 Reduced lead-time \n\u2022 Tripled productivity of the robotic door welding process \n\u2022 Perfect weld quality thanks to robotised welding<\/p>\n
\u201cWe automatise those processes whose robotisation brings real benefits. Using modern technologies, we improve the quality of production processes and, importantly, we increase the safety of operators\u2019 work. Now, we achieve excellent weld quality and high productivity.\u201d said Maciej Socha, Director of Fencing Systems and Corrosion Protection Department, WI\u015aNIOWSKI<\/p><\/blockquote>\n
About the company<\/h2>\n
WI\u015aNIOWSKI has nearly 30 years of experience in the construction industry. Investment in new technologies, improving quality and extending the offer, as well as innovativeness and entering new markets are the features which have made it a leader in its industry.WI\u015aNIOWSKI is a proof that Polish companies can be successful not only in domestic markets but also foreign ones. The WI\u015aNIOWSKI brand products are sold in 2500 outlets in Europe. Currently, the company employs nearly 1700 people.<\/p>\nRegistered office of WI\u015aNIOWSKI in Wielog\u0142owy<\/figcaption><\/figure>\n
WI\u015aNIOWSKI carries out production based on an Integrated<\/h2>\n
Quality Management System. All components of WI\u015aNIOWSKI industrial fences and gates are laser cut, robot welded and subjectedto the best anticorrosive protection methods in the form of galvanising and powder coating. Zinc coating obtained by immersing a chemically cleaned construction in a liquid zinc protects elements of the WI\u015aNIOWSKI fences against corrosion for decades. The aesthetic and unique look of the final product is additionally provided by polyester protective coating in any of over 200 RAL colours.<\/p>\n
The smartCONNECTED idea from the WI\u015aNIOWSKI brand is the next stage of technological revolution. Just as several years ago automatic gates revolutionised the market of garage and fencing gates, now their introduction to the Internet of Things will improve the standard of living.<\/p>\nA bird\u2019s eye view of the WI\u015aNIOWSKI company facilities<\/figcaption><\/figure>\n
Challenges<\/h2>\n
The concept of robotised welding of fencing systems, which are one of the key product groups in the WI\u015aNIOWSKI company\u2019s offer, emerged in the Management Board\u2019s plans several years ago. Due to the wide range of types and sizes of manufactured fences, automation of this process at WI\u015aNIOWSKI was a very difficult undertaking that was implemented in two stages.<\/p>\n
The first stage was carried out in 2014\/2015, when the first station for robotic welding of fencing systems for individual customers was completed. In 2016\/2017, together with ASTOR and two integrators: Zelkon and Acars, phase two was implemented \u2013 automation of welding industrial fencing systems and robotic cleaning of mesh panels. \nIn the welding automation process, ASTOR delivered state-ofthe-art robots and control systems as well as added value: optimisation of a larger process \u2013 order flow and execution, supporting the \nWI\u015aNIOWSKI\u2019s comprehensive customer service strategy.<\/p>\n
Project implementation<\/h2>\n
Orders are automated as soon as they are placed at the point of sale. The software developed and implemented by the ACARS integrator ensures a smooth order flow: orders stored in the ERP system \nare automatically converted into a software for industrial robots \u2013 the system autoconfigures itself for the welding process of the product according to the order placed in the system. This makes it possible to carry out individualised production on a mass scale.<\/p>\nFencing constructor at WI\u015aNIOWSKI during product configuration in the ERP system<\/figcaption><\/figure>\n
The ASTOR Green Welding station, built by integrators Zelkon and ACARS, operates using two Kawasaki palletizing robot industrial welding robots and the Fronius welding equipment. The robots move on a 17-metre track, which makes it possible to weld gates of large size. The robots are mounted on column-and-boom manipulators \u2013 this solution allows to optimise performance and maximise the working range of the robots.<\/p>\n
\u201cThe achieved degree of automation enables full process control and high manufacturing flexibility. Thanks to the integration of the ERP system data with the production system, the time of preparing a new product is significantly shorter. The solution, based on state-of-the-art Kawasaki industrial robots, supports the implementation of the Customer\u2019s business objectives and is in line with the idea of Industry 4.0.\u201d\u2013 Adam Pajda, Project Manager, Control systems <\/span>and robotics specialist, ASTOR.<\/span><\/p><\/blockquote>\n
The robots also work with the ASTOR Green Welding positioners. Using two similar turntables makes the workstations very versatile \u2013 the robots can simultaneously weld one object using the larger positioner or work independently on both workstations, manufacturing two gates at the same time.<\/p>\nThe ASTOR Welding workstation \u2013 the Kawasaki RA006L industrial robots<\/figcaption><\/figure>\n
The modularity of the ASTOR positioners allows the system to be further expanded or modified to meet new production plant needs.<\/p>\n
\u201cThe implemented solution is an incredible convenience for operators! What does an operator need to know? First of all, they have to know the sequence of the system, assemble a product with the right elements in the right order on the machine, switch on the button and control the welding process\u201d \u2013 summarises Mariusz Le\u015bniak, robotic welding line operator at WI\u015aNIOWSKI.<\/p><\/blockquote>\n
An additional benefit for the operators of the station is the use of automatically controlled basins under the turntables, which are recessed into the floor when the gate rotates and are levelled with the floor during assembly and disassembly of the gate by the operators. This solution simplifies work and ensures the safety of employees. The user interface is the Astraada panel computer equipped with the Wonderware InTouch software which, apart from being the tool controlling the ASTOR Green Welding system, acts as a link between the WI\u015aNIOWSKI internal systems and the workstation software.<\/p>\n
The brain of the entire system is GE Automation&Controls\u2019 flagship PACSystems RX3i controller. It provides continuous communication between the system components and controls its operation.<\/p>\nAn operator during handling of a welding station control panel<\/figcaption><\/figure>\n
Benefits<\/h2>\n
Significant time savings have also been achieved in the order fulfilment process, and the work of programmers and welding station operators has been optimised. The robots ensure repeatable welding quality. Welds are exceptionally aesthetic and perfectly prepared for further production stages. The use of robots makes it possible to improve operators\u2019 professional skills, also thanks to training delivered by ASTOR.<\/p>\n
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Implementation of the system made it possible to systematise the production process \u2013 from production planning, through its execution to the quality of the final product. This process has become more predictable and accurate. The system has also made it possible to shorten the execution time of serial orders \u2013 mainly in the context of export orders. The system was introduced in those locations where it was necessary to perform repetitive and monotonous activities and where working conditions were onerous for people.<\/p>\n
The robotisation of production ensured an increase in productivity, made it possible to improve quality and stabilise technological processes, and additionally reduced the time of performing operations. The introduction of this system also provided the possibility of optimal management of the production hall space. Moreover, automation allowed for maintaining the dynamics and fluency of production, as well as for manufacturing according to individual orders.<\/p>\n
The technological revolution we are witnessing is fundamentally changing the way we live and work. In a business context, this means that customer expectations are constantly rising. Nowadays, it is no longer enough to have a product of excellent quality. It must be designed in such a way that it best meets the individual needs of the recipient.<\/p>\n
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