Systems Exceeds Production with Robot Upgrade

Systems LLC, located in Malvern, AR, has been a leading manufacturer of loading dock equipment for over 60 years. Producing brands including Poweramp®, DLM®, and McGuire®, Systems maintains its focus on reliable and high-quality products. For decades, it has relied on WELSCO, a nexAir company, for welding supplies, safety equipment, gases, and consumables – building a trusted partnership that continues to provide dependable solutions. In the summer of 2024, the Systems Plant Management Team requested to meet with its Territory Manager to find a method for increasing production. At the time, its one-arm robots were not meeting supply expectations. The goal was to weld 600 dock levelers a week, but its team had to work overtime, sometimes on the weekends, to meet this target.

Acquainted with its process, the Territory Manager suggested the company upgrade to a pair of two-arm Miller PerformArc® robots to boost its performance. The WELSCO and Systems teams collaborated on a time study, comparing the results of the new equipment to determine its expected cycle times. After verifying this switch would aid production significantly, Systems ordered the product. Within the first week of its installation, the new equipment had not just met but exceeded its goals. The Territory Manager explains, “With the support of nexAir’s automation resources, we exceeded our productivity goals. Being on the front lines with our customers, it’s incredibly reassuring to have such a robust set of tools at our disposal to deliver real value. This capability is what truly differentiates nexAir from the competition.”

While Systems was hoping for a 25% increase in production capabilities, the upgrade significantly outperformed its expectations, returning over 47%. In light of these changes, the company is now able to meet production needs in a standard workweek substantially reducing labor costs. The new equipment reinforces the company’s focus on reliability and high quality – all while saving time and expenses. A Systems Manufacturing Engineer expressed, “We were facing two main issues with our robot systems – our operations outgrew production capabilities and replacement parts became increasingly difficult to source due to age. In collaboration with WELSCO, we were able to implement new robotics while retaining our current structure. Two weeks after installing the new equipment, we were meeting production goals with significant capacity for future growth.”