Developing reliability centered maintenance in automotive robotic welding machines for a tier 1 supplier

Abstract

The study highlights the effectiveness of FMEA in robotic spot-welding operations, providing a systematic approach to enhancing performance in an automotive assembly line. Robotic welding industries depend on mechanized, programmable tools to automate welding processes, ensuring efficiency, reliability, and effective material handling. In the automotive sector, Tier 1 suppliers utilize robotic welding machines to produce high volumes of welded assemblies, with daily output exceeding 450 units. However, frequent equipment downtime due to maintenance challenges disrupts productivity and impacts customer satisfaction. This study aims to develop a Reliability-Centered Maintenance (RCM) approach for robotic welding industries, optimizing machine uptime, enhancing product quality, and reducing financial losses caused by unexpected failures. A 3-year dataset was analysed to identify the primary causes of downtime and their associated costs. Failure Modes and Effects Analysis (FMEA) was applied to assess failure modes, determine root causes, and calculate Risk Priority Numbers (RPNs), thereby formulating corrective actions to mitigate recurring failures and enhance operational efficiency. Findings revealed that maintenance-related issues accounted for 79% of total downtime, resulting in financial losses of R2,281,508.82 over 3 years. The application of FMEA provided a structured framework for prioritizing critical failure modes and implementing targeted corrective measures to reduce downtime and enhance overall reliability. To sustain high productivity and quality, it is recommended that robotic welding industries adopt proactive maintenance strategies based on FMEA findings. Regular monitoring, predictive maintenance, and workforce training will help minimize machine failures and optimize operational efficiency.