Simulation of a welding station with RobotStudio

Industrial robotic arms are key factors for smart manufacturing in the Industry 4.0 era. Technical and financial information are essential to robotic welding investment decisions, but the literature on analytical processes is lacking. This research proposes the use of the ECRS framework in enhancing welding processes, simulating workstations with RobotStudio, comparing productivity, and evaluating financial feasibility. The framework was applied to the manufacturing of off-road front bumpers. Results show that robotic welding reduces working time by 82.3%, increases productivity 5.64-fold, and reduces operational costs by 94.67%. The simple payback period is 4.65 years, and the discounted payback period is 5.73–5.84 years, depending on investing capital. Change in welder wage has the largest effect on the net present value and internal rate of return of the project, whereas change in electricity cost has the least effect.