Turnaround for welding business with close to 300% increase in efficiency

Based in the City of Ruse, Bulgaria, Kosev Ltd. has partnered with KUKA for the introduction of a robotic welding solution in a bid to wrestle with growing customer demand and to urgently boost process efficiency.

With a workforce of 45 skilled workers and specializing in welded metal constructions and steel components, Kosev Ltd. caters to industries including energy, construction, and building machinery. Product portfolio spans telescopic and articulated booms, crowd control barriers, and accessories for wind towers and construction equipment.

“Commitment to quality and innovation has positioned us as a reliable partner for a range of EU customers”, says Milen Kosev, Managing Partner. “So it has become imperative for us to continually invest in state-of-the-art technology to enhance product quality. Today, our manufacturing facility features advanced equipment from leading brands, ensuring precise engineering and manufacturing capabilities.”

Let’s handle this

Before automation, Kosev Ltd. relied heavily on manual welding. While in many ways effective, manual welding has presented several challenges to Kosev such as quality inconsistencies and a chronic shortage of skilled hands among others, coupled with growing demand for the company’s products.

Manual welding has often resulted in uneven seam shapes and heights, requiring additional sanding and cleaning to meet customer specifications. Meanwhile, the company, like many other businesses in Bulgaria, has faced a deficit of skilled welders, limiting its manufacturing capacity and operational flexibility. Furthermore, manual welding processes have failed to keep pace with growing order volumes, leading to extended production timelines. Extra time and allocation of resources have eventually resulted in increased production costs.

All this has made the company urgently consider an innovative tech solution. To tackle these issues Kosev LTD. addressed KUKA for the implementation of a robotic welding system.

“The system enables the welding of various frames made from mild steel”, explains Milen Kosev. “Frames are secured on two rotary positioners, allowing operators to alternate between tables seamlessly. At the end of the day, this setup ensures continuous operation and increased efficiency.”

The way out and ahead

KUKA’s robotic welding system is made up of the following components: a robot; a linear positioner; two rotary positioners; welding equipment including Fronius with CycleStep technology for precise seam control, and additional equipment featuring a Binzel torch cleaning and cutting station.

Offering outstanding flexibility, the system is equipped with KUKA TouchSense technology package, enabling it to weld different components, including metal pallets. Automation is key: integrated tools for wire cutting, torch cleaning, and nozzle spraying minimize manual intervention. Finally, the system displays a healthy degree of operator simplicity, with basic operators able to handle the robotic cell with minimal training, focusing on workpiece exchange and routine checks.

Outcomes & benefits

The introduction of robotic welding has delivered significant advantages for Kosev LTD. Production efficiency increased by 200-300%, enabling the company to handle larger order volumes and meet tight deadlines. The precision of the KUKA robot, combined with Fronius’ CycleStep technology, ensures consistent welding seams that meet customer standards without requiring additional sanding or cleaning. Reduced rework and waste have slashed production costs, while the need to hire highly specialized welders has been minimized. The system’s modular design allows Kosev LTD. to adapt to various production requirements, ensuring long-term value. Simplified operations have reduced the physical strain on workers and enhanced workplace efficiency.

We are very happy with our partnership with KUKA. KUKA has supported us for a successful transition to automated welding which is a new era for the company. The implementation of this innovative solution has positioned us for sustained growth and operational excellence in the strongly competitive manufacturing sector.

Milen Kosev - CEO of Kosev Ltd.

Encouraged by great results, the company already plans to expand its automation capabilities. They are evaluating other robotic systems to further optimize production processes and meet the growing demands of its European customers. With its focus on further automation, Kosev LTD. continues to exemplify a forward-thinking approach to industrial innovation.

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