The company chose Motoman to supply a twin-robot MIG welding cell with powered turntable with the assistance of Malvern-based integrator, Bauromat UK. Wild Springs had used spot welding cells from Motoman since the 1980s. According to Tim Clews, project manager at the Redditch factory, the ongoing reliability of these early cells and the good service back-up over the years gave Wild every reason to return to the same supplier for this project.

The Astra seat frame comprises eleven formed components made from round, mild steel wire of 5 mm diameter, which are placed by an operator into a bespoke jig. During this time, 20 welds are deposited by the two robots to produce the previous frame. The turntable then swings through 180 degrees in a matter of seconds to present the unwelded assembly to the robots and the welded frame to the operator for unloading, ensuring virtually uninterrupted production. TAKT time is one minute, around 25 per cent less than for an equivalent spot welding cycle.

Most of Wild’s experience of seat frame manufacture had involved spot welding in robot cells, including for Jaguar, Land Rover, Range Rover, Nissan, Honda, Toyota and for the BMW Mini convertible. It does, however, have long experience in large volume, robotic arc welding of automotive products from 0.5 mm to 13 mm diameter wire, such as seat parts, exhaust hangers and various components requiring sub assembly. Other products produced at the Redditch factory include float rods, trim wires and springs for doors, throttles and thermostats.

In addition to the Redditch site, the Wild Group has manufacturing facilities in Birmingham and Hungary with significant pressing and assembly capabilities. The former site has recently relocated to a new, purpose-built facility.