In a bid to enhance efficiency and elevate the quality of our railcar production, we have recently integrated a cutting-edge welding robot into our in-house workshop at WSO in Ostróda, Poland. This move marks a significant advancement in the realm of railcar manufacturing, promising streamlined processes and heightened precision.
Railcar Cross Beams and Head Piece Production – Progress on Track
Programming the welding robot signifies a major milestone in the manufacturing process at GATX Rail Europe. Our team has completed the programming of the robot for the welding seam for the railcar’s cross beams, a crucial component in the construction. The second implementation for the robot commenced earlier this year for the head pieces. Our team has started with the prototype fabrication and is now ready to swiftly transition to full-scale production. “The incorporation of the welding robot in our railcar assembly process expedites the entire process, particularly in the creation of underframes,” explains Slawomir Garwacki, Managing Director at WSO. The integration of the welding robot not only accelerates production, but also elevates the quality of welds, surpassing traditional methods.Validating Welding Procedures – Ensuring Quality and Consistency
Ensuring the integrity of welding processes is paramount in the production of railcars. At GATX Rail Europe, we meticulously validate welding procedures, subjecting them to rigorous scrutiny and testing. Once approved, the welding robot executes the tasks with unparalleled precision, resulting in welds that exceed industry standards, which is also certified by independent inspectors. This means that during the welding qualification process each welded piece requires a separate 3D Model and programming. When the robot executes the weld, the resulting piece is transferred to a lab for inspection and a Welding Procedure Qualification Report accompanies each weld type. Once both the piece and the report are certified, production begins.
Upskilling the Workshop’s Workforce
“We also recognize that responsibility of upskilling our workforce,” adds Slawomir. He continues, “Digitalization and automation have reached our workshops and new skillsets are required to handle welding robots now, which is why we have invested in training programs to equip staff with the necessary expertise in robotic operation and programming.” This initiative not only enhances operational efficiency, but also underscores the company’s commitment to fostering technological proficiency among its workforce.
GATX Rail Europe is ready to optimize its in-house assembly of tank railcars and limited editions of new-built railcars. As the welding robot continues to be programed for new welding tasks, including the fabrication of additional components, our teams are ready to embrace the new way of working in the workshop.
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