Search

• Tooling Solutions

      CIC Tools
      Industrial Fixtures
      Spec Grade Fixtures

• Control Options
• Workcell Packages
• Automation Peripherals

The welding environment presents unique challenges for manufacturers. With over twenty-five year's experience, Genesis knows what to expect. This knowledge is essential when designing reliable, capable fixtures. Genesis designs world-class welding fixtures that withstand the harsh affects of welding by using the right materials and designing robust, capable fixtures that include spatter protection appropriate for the intended environment. When possible, we utilize standard, off-the-shelf components - greatly reducing the amount of machining level customization. This practice improves uptime by minimizing unscheduled maintenance. The result is lower repair and replacement cost, and quicker preventative maintenance turnaround time. Let us help lower your total life cycle costs; by partnering with Genesis, you get a robust, capable, integrated tooling solution.

VARIATION MANAGEMENT

In today's increasingly competitive manufacturing marketplace, the key to success hinges on the ability to deliver quality products, on time and within budget. Variation Management provides product and process analysis and insight while fostering collaboration that leads to production enhancement, quality assurance, and improved thru-put. Our variation management team can answer your vital production concerns, the "analytical approach" yields high quality, reliable tooling and arc welding products that help you outperform your competition.

The Genesis team works in collaboration to identify variation in prime part designs and manufacturing processes by employing computer simulated dimensional capability analysis. By combining two critical success elements, Variation Management and fixture design know-how, Genesis offers metal fabricators a unique, new approach for dimensional control and arc welding fixture quality.

Variation Management Example - In this example, multiple brackets are welded together. The dimensional analysis revealed the brackets variation exceeded weld joint location requirements for robotic welding. The analysis results show excessive variation at the weld joint. (1) This condition, if not corrected would lead to weld quality issues (2) and production issues, i.e., lower thru-put, higher rework and reduced profit. Using the analysis results and fixture design experience, the datum logic was altered to "manage" the variation away from the weld joint. Optimizing the welding process while verifying product dimensional quality helped this customer achieve their quality and production goals.

THE PROBLEM

Component parts are never perfect. CAD is nominal, manufacturing is not; manufacturing processes vary. Variation at critical locations can make part fit-up difficult, lower thru-put and reduce system production effectiveness. Automated robotic welding requires weld joint locations and conditions to be tightly controlled. Weld Joint design and process configuration becomes a critical consideration.

THE SOLUTION

• Predict variation in your system (processes, parts, people)
• Identify where variation exists, utilize Variation Simulation Analysis to pinpoint dimensional "hotspots"
• Minimize the variation by optimizing product & process
• Accommodate the remaining variation through process techniques such as, smart fixturing, Touch Sensing, Thru Arc Seam Tracking, and/or weave welding.

THE RESULTS

• Reduces robot touch up time
• Minimizes tooling adjustment (tampering)
• Improves quality
• Increases through-put
• Lowers overall product life cycle cost

 

 

 

• GDTS Brochure