A manual MIG welding operation had to become a two-robot cell in an existing bay that shared a wall with a manual work area, with a 180 A supply limit and a works council that had to approve the change.
Reach and cycle time simulation for three robot configurations before any hardware was specified
Safety architecture designed to ISO 13849 with performance level calculated, not assumed
Fume extraction assessed for the shared bay so the manual area was not degraded
Electrical load balanced within the 180 A limit by sequencing the positioner and welders
Works council presentation focused on what changed for the operators, which is what actually unlocked approval
A 7-storey 1970s office block had to stay occupied through a seismic retrofit. The original drawings were incomplete, concrete strength varied by 40% between cores, and the client could not vacate more than one floor at a time.
A die-cast aluminium pump housing was 22% over its mass target but the tool was already cut. A new tool would have cost the programme five months.
A 42 MWp plant's provisional connection offer carried a reactive capability condition the originally specified inverters could not meet across the full voltage range. The issue surfaced three weeks before financial close.
