Automobile Manufacturer Reduces Robotic Welder Parameter Development Time By 76% With Kure
PROJECT SUMMARY
The problem: This automobile manufacturer faced a major challenge with its robotic welding process—delays in approving welding parameter changes created inefficiencies, safety risks, and potential production bottlenecks. The process took an average of 6.4 weeks, with some approval taking up to 8 weeks.
Determined to make things better, the organization turned to Kure, an AI-powered process improvement platform. Kure helped the team analyze the problem and guided them step by step through a structured improvement process. With Kure’s support, the team reduced welding parameter approval times by an impressive 76%.
The Problem
Robotic welding is a key part of modern vehicle production. It ensures parts are securely connected, safely and efficiently. But at this manufacturer, getting approvals for updates to welding parameters was taking far too long—an average of 6.4 weeks, with some changes taking up to 8 weeks. These delays led to several problems:
Slower production improvements: Waiting weeks for approval meant quality upgrades were put on hold.
Increased safety concerns: Long wait times made it harder to fix issues like weld expulsion, which could pose a safety risk.
Workflow slowdowns: Extended approval timelines created roadblocks in the production process.
It was clear the company needed a better way to make timely, safe, and effective changes to its robotic welding systems.
To fix the issue, a skilled team was assembled, led by a project manager using Kure’s AI-powered workflow to guide the way. Kure walked the team through the proven DMAIC methodology (Define, Measure, Analyze, Improve, Control), offering helpful examples, real-time suggestions, and data insights along the way. This allowed the team to focus more on solving problems and less on figuring out what steps to take.
The Root Causes
Using Kure’s built-in analysis tools and guidance, the team uncovered the real issues slowing things down:
No clear decision-maker: Too many people were involved in approvals, but no one owned the final decision.
Lack of urgency for critical issues: There was no fast-track option for changes that needed immediate attention.
Without a focused approach or clear ownership, the approval process kept dragging out.
The Solutions
Kure’s AI workflow helped the team zero in on practical, high-impact solutions:
Appointing a Subject Matter Expert (SME): A robotic welding expert was officially assigned as the go-to person for approving changes. With a single point of authority, decisions could now be made faster and more confidently.
Creating an Emergency Approval Pathway: For safety-critical or time-sensitive updates, the team built a streamlined process that allowed for same-day approval, with quick sign-off from internal leadership.
These changes were easy to implement thanks to Kure’s step-by-step support, which helped the team stay focused, efficient, and aligned.
The Results
The improvements made a big difference:
Approval times dropped from 6.4 weeks to just 1.5 weeks—a 76% improvement.
Emergency changes could now be approved immediately, helping prevent delays in safety or quality fixes.
Production moved faster, with fewer interruptions caused by long waits.
Quality and safety improved, as issues could be resolved before they caused bigger problems.
Thanks to Kure, the team was able to complete the entire improvement project up to three times faster than traditional methods—and with better results.
Conclusion
This project shows just how powerful smart tools and teamwork can be. With the help of Kure’s AI-powered process improvement workflow, the organization not only solved a major delay but also created a repeatable approach to fix future problems.
Kure’s user-friendly design, helpful examples, and real-time data analysis made it easy for the team to stay on track and make decisions with confidence. By cutting approval times by 76%, the company boosted safety, speed, and quality across its production lines.
Now, with Kure as a trusted problem-solving partner, this manufacturer is better prepared than ever to take on new challenges and keep driving forward in the competitive world of automotive manufacturing.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
