Improving Efficiency and Safety with a UR5e Cobot Broach Machine Tending Solution
Some machines are essential to production but difficult to staff.
For a precision machining components manufacturer in Wisconsin, that was the case with a broach machine producing small brass fittings used in fire extinguishers. The process was fully manual, requiring an operator to load parts continuously throughout the shift in a dirty, oil-heavy environment.
The work was repetitive and required constant attention. Plus, it tied up valuable labor on a task that added little strategic value.
The customer began exploring collaborative robots to improve efficiency and make the role more operator-friendly. That conversation led to a broach machine tending solution built around the UR5e cobot.
The Automation Solution
The final system was designed for reliability in a challenging machining environment while remaining flexible and easy to deploy.
System Overview
- Customer Type: Precision Machining Components Manufacturer
- Application: Broach Machine Tending
- Cobot: Universal-Robots UR5e
- Gripper: PHD
- Base: Easy Robotics
- End-of-Arm Tooling: Custom-built to address machine clearances
Because the broach machine was older, there were minor electrical integration challenges that required on-site troubleshooting. Even with those adjustments, the system was installed and running production within approximately 3–4 hours of arrival.
For the first robot in the facility, that speed and simplicity made a strong impression.
From Full-Time Tending to Minimal Oversight
Prior to automation, the broach machine required 100% operator attention. After implementation, the workflow changed dramatically.
The cobot now:
- Loads parts consistently
- Processes a part approximately every 12.5 seconds
- Allows staging of up to 500 parts at a time
- Runs unattended for extended periods after a brief setup
Instead of dedicating one person to the machine full-time, the operation now requires only periodic check-ins. Operators can stage parts, start the system, and shift their focus to higher-value work elsewhere in the facility.
The result is improved labor utilization without compromising production output.
Clean, Consistent, and Operator-Friendly
Machining environments can be tough on both equipment and people. Oil, debris, and repetitive motion create a less-than-ideal workstation.
The cobot solution was designed to handle those conditions reliably, delivering consistent part handling even in dirty and oily environments. Beyond productivity gains, automation reduced operator exposure to repetitive tasks and improved overall shop-floor satisfaction.
In fact, the immediate response from employees made it clear that automation wasn’t viewed as a threat, it was welcomed as a practical improvement.
“One of the most rewarding parts of this project was seeing the team’s reaction,” said Dan Carney, GCG Robotics Consultant. “They were genuinely happy to let the robot handle this repetitive, messy task.”
Key Benefits Delivered by GCG
This broach tending application highlights how collaborative automation can deliver measurable and cultural impact at the same time.
Operational Benefits:
- Rapid installation
- Minimal downtime
- Reliable, repeatable part handling
- Increased unattended runtime
- Improved labor allocation
Workforce Benefits:
- Reduced monotonous tasks
- Less exposure to messy environments
- Higher job satisfaction
- Positive reception to first-time automation
A Practical First Step into Robotics
For this manufacturer, the broach tending project served as an accessible entry point into collaborative automation. The application was well-defined, the ROI was clear, and the implementation was straightforward.
Cobots like the UR5e are particularly well-suited for machine tending applications where:
- Operators are tied to repetitive load/unload cycles
- Staffing is difficult
- Safety or cleanliness is a concern
- Production consistency is critical
By automating a single demanding machine, the company improved efficiency, strengthened operator morale, and demonstrated how robotics can integrate seamlessly into a traditional machining environment.
“This project is a great example of how collaborative robots can transform a labor-intensive process without disrupting production,” said Dan Carney.
Collaborative robots are transforming labor-intensive machining tasks making them safer, more efficient, and more sustainable for today’s workforce. If you’re evaluating machine tending automation or exploring cobots for the first time, connect with one of our cobot experts:
E: cobots@gogcg.com | T: 262-250-2120