Modine, a leader in performance technology and climate solutions, faced a growing labor shortage and inefficiencies in their high-mix, low-volume welding process.
Kinetic Technologies stepped in, delivering a custom cobot solution in record time, transforming their operations and setting the stage for future growth.
In this Case Study
The Challenge ›
The Implementation ›
The Results ›
Conclusion ›
The Challenge
Modine was juggling several challenges that impacted their production:
• Skilled welders were hard to find, making it difficult to scale manual welding operations.
• Existing cobots were collecting dust due to poor fixturing and setup, limiting their potential.
• High-mix, low-volume welding required flexibility that wasn’t supported by their current systems.
The pressure mounted when demand spiked.
The pressure mounted when demand spiked.
“The biggest challenge was determining the right positioners and how to implement them. We needed a partner who could fully support us and keep things simple. Simplicity was our key goal,” shared Nilesh Tapdiya, Continuous Improvement Manager at Modine Manufacturing Company.
With little margin for error, they needed an automation integrator who could deliver results without asking them to bend their requirements.
The Implementation
Kinetic Technologies approached the project with creativity and determination, focusing on Modine’s specific needs.
• Ingenious Design: Kinetic mounted the cobot upside-down on an overhead gantry, increasing its reach by 30%. This allowed more parts to fit within the cell, boosting efficiency while maintaining quality.
“They showed real ingenuity by mounting the cobot upside-down on an overhead gantry, which increased its reach by over 30%. That innovative approach allowed us to fit more parts into the cell.”
– Nilesh Tapdiya
• Collaborative Approach: Weekly calls kept the teams aligned and proactive. Even when supplier delays threatened the timeline, Kinetic found workarounds, like simulating the system with a backup cobot.
“Kinetic never took no for an answer. Every time, they came with what else we could do to still keep the same deadline.”
– Nilesh Tapdiya
• Fast Deployment: From purchase order to execution, Kinetic completed the project in just eight weeks.
“The demand was already there, and Kinetic did all that in eight weeks. That was super impressive.”
– Nilesh Tapdiya
The Results
The results of the collaboration were extraordinary:
• Throughput tripled for most parts and quadrupled for key components.
• Improved fixtures and programming improved quality, reducing defects and lowering costs.
“Before implementing the cobots, 100% of our welding hours were manual. Now, about 80% of our standard welding hours come from automation,” said Nilesh Tapdiya. “Our performance has improved threefold for many parts, and even fourfold for some key components.”
Conclusion
Modine’s successful project with Kinetic Technologies highlights the value of finding the right automation integrator.
Kinetic Technologies ability to innovate, collaborate, and deliver under pressure solved Modine’s immediate challenges and laid the groundwork for future projects. Today, Modine has five cobot cells in operation and has earned an AWS Welding Excellence Award.
If your operation is struggling with labor shortages and automation challenges, Kinetic Technologies is the partner that can turn your vision into reality.
