Welding automation sounds like large-scale industry, but it is also effective in medium-sized companies. If you want to keep welding processes stable today, despite a lack of skilled workers and changing orders, you need methods that work quickly and deliver cleanly. It quickly becomes clear what automation in welding really brings: reproducible quality, less rework and cost-effectiveness that often takes effect earlier than expected. Find out how this works and which welding automation for SMEs is right for your business here.
What does welding automation mean for small and medium-sized companies?
Welding automation for SMEs refers to all forms of automation that support or completely take over manual welding processes. This ranges from simple mechanized welding devices to semi-automated welding systems and complete welding robot cells. SMEs - i.e. companies with fewer than 250 employees and limited annual turnover - have very different requirements to large companies: They need smaller quantities, use changing components and have limited investment budgets and a high degree of flexibility.
The important thing is: Automation does not replace people, but relieves them. In this way, welding automation complements the existing expertise of skilled workers in a positive way, while making small companies less dependent on staff shortages - especially in times of sickness waves. In practice, the introduction is almost always gradual and gradually adapts to the company and the specific welding tasks.
Why welding automation makes economic sense for SMEs
Automated welding processes are reproducible, which means that they always work with identical welding parameters, consistent speed and constant seam quality. Compared to manual welding processes, this significantly reduces rejects, while also reducing rework.
In practice, this has a clear impact on economic efficiency: productivity can increase by 150 to 300 percent, while scrap rates fall by 50 to 80 percent. As precise weld seams require less filler material, overall material consumption is also reduced. For these reasons, an investment often pays for itself within one to three years - and this can be a decisive competitive advantage for SMEs.
Costs and funding opportunities: A realistic look at the new welding technology
The costs for welding automation vary from manufacturer to manufacturer. However, the following can be roughly estimated: A manual welder costs around 55,000 to 70,000 euros per year, including non-wage labor costs. If only half of this working time is replaced by automation, there are direct savings of around 27,500 to 35,000 euros per year. Many automation solutions also pay for themselves more quickly than is usually expected due to the significantly reduced rework and shorter throughput times. In addition, certain subsidy programs or leasing models can further facilitate the initial investment.
Welding robot, cobot or mechanized solution? A realistic comparison
Not all welding automation systems are the same: for SMEs alone, there are several systems to choose from that differ in terms of their degree of automation, flexibility and cost.
- Classic welding robots: very powerful, high precision. Ideal for complex welding tasks and long-term expansions.
- Collaborative robots (cobots): Entry level often from around €25,000. Ideally suited for simple, repetitive welding processes and smaller series.
- Mechanized welding systems: For example, longitudinal seam welding machines that create reproducible seams with little set-up effort.
Typical welding tasks that can be easily automated
One thing is certain: welding automation is particularly useful where welding processes are repeated regularly. These include longitudinal seams, circumferential seams, corner seams or similar joints on components. In practice, it has also proven to be a good idea to start with a compact pilot project - for example with a family of components. Automated systems weld these components reproducibly and reduce post-processing by up to 92 percent. This creates quickly measurable results and general acceptance in the company.
Involving employees - automation as a relief, not a replacement
Welding automation for SMEs counteracts the shortage of skilled workers in a targeted manner - and this can pay off quickly. Automation should never replace the work of existing skilled workers, but merely make it easier. For example, automated systems usually take over monotonous, physically demanding work, while staff can concentrate on more challenging tasks. On top of this, new roles are quickly created, as people are needed to operate and monitor the system or carry out quality checks.
The good thing about it: After instruction, the welding systems can often be operated by semi-skilled workers. This increases job satisfaction, reduces health risks and noticeably reduces the workload on the team. Schnelldorfer Maschinenbau will be happy to provide training for your entire team so that all employees can be easily introduced to the world of automated welding.
Which welding processes can be automated?
Many common welding processes can already be automated. MIG and MAG welding are particularly suitable for high welding speeds and larger quantities. TIG welding, on the other hand, is used wherever maximum precision and clean seams are required. This is often the case with stainless steel or aluminum. Last but not least, there are also automated plasma and laser welding processes, which score points with their low heat input and minimal material deformation. Whichever welding process you use: There are always constant welding parameters in the automated systems and therefore a consistently high seam quality.
Longitudinal seam welding machines as an automation solution for SMEs
Longitudinal seam welding machines such as the LINEARWELD series from Schnelldorfer Maschinenbau are a practical automation solution for SMEs. They are ideal for straight weld seams on sheet metal, pipes or profiles and always deliver strong, reproducible results - with minimal set-up effort. The good thing about it: thanks to the modular design, workpiece lengths of up to 4,100 mm and material thicknesses of up to 15 mm can be processed. For many companies, these welding systems are therefore an all-round economical alternative or addition to the welding robot cell.
Welding automation for SMEs - your competitive advantage with Schnelldorfer Maschinenbau
Welding automation for SMEs is now both affordable and economically viable. With the right planning and an experienced partner like Schnelldorfer Maschinenbau at your side, the step towards automation is a guaranteed promise of success. The goal is clear: to relieve your employees and increase profitability at the same time.
Let us advise you now on automated welding and take the step towards future-proof welding technology together with us. We look forward to hearing from you!
Frequently asked questions (FAQ)
When does welding automation start to pay off for SMEs?
Even for regularly recurring welding tasks and small series, welding automation can be worthwhile. However, it is not only the number of pieces that is decisive, but above all the frequency of repetition and the time required per welding process.
Are welding robots suitable for small companies?
Yes, modern welding robots and cobots are specially designed to meet the requirements of SMEs and can be used there flexibly.
Can existing welding equipment be used for automated welding?
In many cases, yes. Mechanized systems can often be combined with existing welding power sources.
How long does amortization take?
Typical amortization periods are between one and three years. The actual duration depends heavily on use, capacity utilization and the actual savings potential.
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