Commonization of Welding Adaptor

An heavy construction equipment manufacturer reached out to ARi on tool design support for designing a common welding adaptor to do full welding of 3 variants.

Project Scope

An India based heavy construction equipment manufacturer reached out to ARi on tool design support for designing a common welding adaptor to do full welding of 3 variants. They have been using 3 different adaptors which led to set up change over time of 2.0 Hrs /variant and also it was not operator friendly due to Safety and Ergo issues . Through simple and efficient design, the team was able to reduce the cycle time by 40 % with improved safety and ergonomic issues and meeting the quality requirements. This improved design resulted on cost savings of USD 2100 by eliminating 2 sets of welding adaptors.


Business Challenges


  • 3 sets of weld adaptors with each setup resulting 2.0 Hrs /changeover.

  • Safety & Ergonomics issues due to poor accessibility of resting and clamping points.

  • Idle time of Robo positioner for availability of overhead crane.

  • 12.0 Sq.mts of space need to store the Weld adaptors.


ARi’s Solutions

The ARi team designed a common adaptor to cover all 3 variants.


ARi’s Value Proposition


  • Set up change over time reduced by 75 %.

  • Eliminated Safety and Ergo issues.

  • Cost saving of USD 2100 by eliminating 2 Adaptors.

  • 8.0 Sq.mts of space saved.


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