increasing productivity in manufacturing

White Paper: Increasing Productivity in Manufacturing with New Weld Technology


Heavy-industry manufacturing lines will always need the ability to weld heavy and complex parts well. The ability to weld around the circumference of a heavy part in manufacturing is a complicated process. One of the newest projects we’ve finished this year has revolutionized our client’s welding process, opening up new possibilities for the future of their company and manufacturing process.

The latest free white paper we’ve published features a heavy-industry project that transformed an unreliable and outdated welding system into a safer, more accurate weld cell that doubled our client’s productivity. Our client’s old system had a history of parts slipping during the welding process, despite using 15,000 lbs of force to keep parts in place. 

Any system that produces imperfect parts during the manufacturing process will slow down production and affect a company’s overall throughput. Our client knew they needed a solution that produced accurate welds, kept parts in place during the process, and kept their line operators safe.

Our engineers are experts at designing new processes that overcome any challenges our clients bring us. This project turned into a special opportunity for us to partner with Miller Electric to beta test a brand new welding system that is the first of its kind on the market! Our team also created a unique spring-loaded tool system that solved our client’s particular frustrations with parts slipping with their old system.

Our client needed a process that could hold parts ranging from 50 to 1,500 lbs without slipping or damaging the part itself. Our solution also needed to automatically recognize parts of different sizes and choose the correct steps and tools for each individual part without manual input. The automated solution required a faster welding system that decreased risk of:

  • Porosity
  • Cracking and other quality issues
  • Decreased risk of part slippage
  • Adaptability of the welding process for a variety of complex parts 

Though the goal for this project felt complicated and impossible at times, our engineering team knew they could design a system that met all of our client’s needs, increase productivity, and decrease safety risks for employees and operators close to the process. The result of our engineers’ expertise was an easy-to-use-system that integrated with their other processes to deliver finished products faster than they thought possible.

In this free white paper, you’ll discover how this custom, adaptable system:

  • Saves time and money through reliable tooling
  • Reduces risk of production being stalled because of imperfections in welded parts
  • Saves time through a unique, advanced welding technology from Miller Electric
  • Reduces safety risks to employees through remote operation

To discover more about how Navus engineers used a cutting-edge welding system to design a custom automation process that worked for our client’s needs, you can read all about it in the free white paper, Increasing Productivity in Manufacturing with New Weld Technology.


Navus Automation Inc. is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision and reliability

Proof of Concept rendering

Proof of Concept: The Evidence of Simulation & Demonstration


Recently we were reminded of how wonderful it is to work with returning customers. A client we regularly work with in medium industry manufacturing had a multi-step system in their facility that cost them hundreds of thousands of dollars to accurately produce manufactured parts. Our engineers thought outside the box, allowing us to brainstorm and come to them with a brand new system that solved their problem with just one additional robot, rather than needing to purchase and integrate large, dedicated equipment


When we partner with you, we don’t just deliver a one-and-done solution. Our delivered solutions open up endless opportunities for your business. We achieve this by proposing solutions others haven’t considered. 


But proving our ability to deliver a comprehensive solution goes beyond a proposal. At Navus. we have the capability to deliver a proof of concept for many of the proposals we offer a client. With a proof of concept, we don’t have to try to convince you that our ideas will work. We show you our solutions in action.

What is Proof of Concept?

At Navus, we provide renderings and visuals when we engineer a solution so you can envision what we have in mind. But in order to actually test the solution, we encourage all clients to consider a proof of concept. This is an important step in any proposed integration solution as it allows the actual solution to be built at a smaller scale so we can show the system in action.


Navus uses state-of-the-art offline programming and simulation software to determine the feasibility of an idea. This happens before the first part is ever cut, fabricated, machined, or coated. This serves to further mitigate risk before building even small-scale test setups, whether to verify cycle time or ensure proper robot reach and accessibility.


If our proposed solution solves the challenges it’s supposed to during the proof of concept phase, then we move forward with building the solution to scale. However, if any part of it fails during the proof of concept phase, we go back to the drawing board. We refuse to deliver a system that is going to make your life harder or potentially fail once integrated in your facility.

Proof of Concept and the Confidence of a Complete Solution

Investing in a new integrated system for your facility shouldn’t go to waste. Innovative ideas can be discussed and proposed, but if they fail during the proof of concept phase, they’re not actual solutions for your needs. At Navus, we’re dedicated to perfecting any solution we propose during the proof of concept phase in order to save you headaches and cost when completing the final system. 


When our client was open to the idea of developing our proposal into a proof of concept, the initial investment was a fraction of the total system cost, and ultimately went a long way in saving them money. We were able to pull most of the parts for the proof of concept from inventory we already had onsite. This allowed us to bring our vision to life without ordering expensive parts prior to integrating the proven solution. This live demonstration was a small investment on our client’s part, but the return gave them so much more. It gave them a solution they could trust.

What Did Proof of Concept Provide For Our Client?

When you’re looking for a solution to a challenge, the last thing you want to do is waste time, money, or resources. Proof of concept testing may seem like an extra step, but it’s one worth taking. Testing a proposed solution every way possible can save you from wasting more time and money down the road if a solution isn’t properly examined.


The proposal we gave our client took a multi-system process they already had and required in their facility, and compacted it into one system using robotics. This solution uses flexible robotics fitted with reusable tooling and inexpensive fixtures that can be used for multiple different parts manufactured in our client’s facility. 


By using our in-house 6-axis industrial robots, PLCs, end of arm tooling, laser scanning/searching technology, force compliant grinding technology, welding capabilities, and custom programming, we built a smaller scale version of our proposed solution. Our client watched the proposal come to life through both simulation and demonstration, giving them the reassurance they needed to move forward with implementation.

Engineering the Smartest Automation Solutions Since 1998

Navus’ ability to solve your challenges ultimately comes down to our team and history of excellence. Every one of our engineers is passionate about solving specific challenges for our clients who partner with us. At Navus, we don’t resort to generic solutions. We’re dedicated to thinking outside of the box to ensure our turn-key system solutions accomplish what you need and solve the challenges you face. Proof of concept is just one way that we provide assurance to every client who hires us that their challenges are solved. 


Partnering with Navus isn’t just about figuring out a solution for your current challenges. Like this particular project shows, we promise to go beyond an initial proposal and offer new ideas and solutions that create a better future for your manufacturing space and company throughout our partnership. When you choose to partner with us for your integration needs, you become a part of the Navus family.


Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.


For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!