Automated Welding for Metal Chairs in Malaysia
Client Profile
Our client is a well-established Malaysian furniture manufacturer specializing in metal chair production. The company faced increasing pressure to scale up output while maintaining consistent weld quality. Manual welding had become a bottleneck. Variations in welds affected chair strength and increased rework, slowing overall production. Ensuring precision and reliability became essential to meet both delivery schedules and customer expectations.
The Challenge:
Before automation, all welding was performed by skilled operators. This approach caused variability in weld quality and limited production efficiency. The client required a solution that could:
- Deliver consistent welding quality across all chairs
- Reduce dependence on operator skill
- Enable manual touch-ups at hard-to-reach weld points
Our Solution:
In 2018, our team implemented a hybrid welding system featuring an OTC six-axis robotic arm paired with a three-axis positioner. The robot handled the primary structural welds, while manual welding was applied for key points that the robot could not reach, such as connections between chair legs and the seat, armrest-to-backrest joints, and intersecting support bars. Pneumatic clamps operated independently to ensure proper positioning during welding, and optimized arc welding parameters along with a user-friendly interface allowed stable operation even for operators with limited automation experience.
Our team managed the full process—from design and robot programming to on-site commissioning—ensuring a smooth transition from fully manual to hybrid robotic welding.
The Outcomes:
- Consistent weld quality meeting structural and visual standards
- Productivity improvement of 25–35% compared to fully manual welding
- Reduced operator fatigue and improved workplace safety
- Established a reliable, repeatable welding process that maintained quality even with new operators.
Following this implementation, the client gained confidence in integrating robotics into their production, establishing a reliable and efficient welding process that supports future improvements in manufacturing operations.
About Aixsen
At Aixsen, we deliver end-to-end industrial automation systems designed for demanding manufacturing environments.
We deliver precision laser cutting, robotic arc welding, and intelligent material handling solutions—designed as standalone systems or integrated lines, fully engineered around your specific process, quality requirements, and output targets.
