Solving the Welding Bottleneck With Robotic Laser Welding
West Coast Manufacturing, a CNC machine shop serving the commercial dishwasher industry in the U.S. and Canada, faced a familiar challenge: rising labor costs and quality issues made some of their manual welding unsustainable. After 2020, welding became their biggest labor problem, limiting both productivity and consistency at a time when demand was growing fast.
The solution? A new approach to collaborative robotic laser welding. By partnering with THG Automation, West Coast Manufacturing was able to replace manual TIG welding with cobot systems – achieving up to 4x more productivity and higher weld quality while reducing the strain on their workforce.
Discovering THG Automation through Universal Robots
West Coast Manufacturing’s President Patrick Hundley first discovered THG Automation while visiting the Universal Robots booth at Fabtech a few years ago. What started as a stop at a tradeshow quickly became a turning point for his organization.
“We really wanted to do business with THG. We liked their professionalism. We liked the guys behind the scenes that helped with support. Something happened where we spiked, and I had to have it NOW. Then I think we ordered three in a row!”
Why Support Matters: WCM’s Choice for Cobot Welding
For WCM, the “aha” moment came from seeing how precise and consistent laser welding could be compared to TIG. Manual welding often caused issues with thinner materials and smaller diameter parts, where excess heat led to warping and rework.
With THG Automation’s cobot welding systems – built on Universal Robots collaborative robots and Fronius welding technology – those problems disappeared.
“We chose THG Automation over other providers because they were willing to stick around and solve these challenges with us. We had another robotic laser welding system in-house before, and we didn’t have that support. Now we have three systems from THG.” – Bryan Montez, Plant Manager”
Collaborating for smarter welding solutions
West Coast Manufacturing’s success didn’t come from an out-of-the-box package – it came from collaboration. The WCM team worked closely with THG Automation to customize the URCap software, adding practical features like wire on/off and stitch welding in circular motion. These upgrades, born directly from WCM’s production needs, are now part of THG’s standard platform.
“We worked with THG on fine-tuning their URCap to offer certain things like wire on, wire off. An example is we needed to stitch weld a part moving in a circle, and they came up with a way to make that possible. Now it’s a standard feature.” – Bryan Montez”
Unlocking Efficiency with Dual-Station Welding
With their THG Automation systems, WCM can take on multiple operations at once. Their dual-station setup – two 4×8 tables – allows operators to load one fixture while another welds, keeping production moving seamlessly.
“In some cases, we have three operations for one part, doing different processes within those stations. Operators are able to load one fixture, hit a button, and get the next operation ready while the system welds the previous one.” – Bryan Montez”
Results That Speak for Themselves
The numbers tell the story: West Coast Manufacturing went from 10–30 parts per hour manually to 45–60 parts per hour with robotic laser welding. At the same time, they reduced rework, improved weld quality, and gave their team tools that make their work easier and more sustainable long-term. With three THG Automation robotic laser welding systems now in operation, West Coast Manufacturing has not only solved its labor and quality challenges but also built a foundation for future growth. As for their thoughts on whether or not you NEED this technology in your facility? “I highly advise it,” Hundley says.
If you’re facing similar challenges or looking to improve your welding throughput, our team is here to help.
Reach out to our fabrication experts to discuss your welding operation and see if a collaborative welding system is the right fit for your shop. We’ll help you explore what’s possible. No pressure, just real answers.
