Despite an industry-wide shortage of skilled welders, Kleeberg has increased productivity by partnering with Novarc Technologies and adopting the Spool Welding Robot (SWR™). The SWR is a welding cobot designed specifically for pipe, small-pressure vessels, and other types of roll welding. With the cobot, Kleeberg has increased welding speed by three to four times on larger pipes.
Kleeberg excels in a wide array of services ranging from sheet metal and mechanical services to design-build projects and custom industrial fabrication. However, they confronted challenges in sustaining uniform welding quality and efficiency, particularly in welding pipes ranging from 4” to 24”. These dimensions were critical in their diverse array of projects, involving complex systems like steam, chilled water, and hot water. Kleeberg aimed to enhance the consistency of their welds and amplify overall welding productivity while maintaining low repair rates.
Novarc’s robust support system, characterized by prompt responsiveness and comprehensive training, facilitated a smooth transition for Kleeberg’s operators, enabling them to master the SWR within a week. With 95% of their welding now conducted using the SWR, Kleeberg has experienced a transformative shift in their welding processes. This advancement not only resolved their immediate challenges but also positioned them as a frontrunner in industrial efficiency and technological adoption. Kleeberg quickly realized a number of benefits from using Novarc’s SWR.
- Accelerated project completion: Kleeberg achieved a substantial reduction in project completion times. Specifically, they can complete welding tasks on 12” pipe joints in just 10 minutes, a significant improvement from their previous timelines.
- Increased welding productivity: The implementation of the SWR resulted in a remarkable increase in productivity, with over 250 factored diameter inches per shift, enhancing the speed by three to four times for pipes ranging from 8” to 14”.
- Significant weld cost savings: Kleeberg achieved substantial cost savings per weld, amounting to approximately $25 for smaller pipes (6–8”) and around $45 for larger pipes (12–14”), exclusive of the Novarc system’s cost.
- Time savings: Overall, the SWR contributed to a 12–15-percent decrease in time in Kleeberg’s operations.
Other companies that have invested in the SWR have not only increased their pipe welding productivity but also dropped their repair rates to less than 1 percent, making them more competitive when bidding on jobs and increasing margins on contracts already won. The collaboration with Novarc Technologies enabled Kleeberg to successfully address key challenges and set new benchmarks in welding productivity and quality.
For more information, visit www.novarctech.com.
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