Production Impact at Clow
- 24 automated production cells deployed across blanking, stamping, and welding
- Blanking output increased by 150-220%, from 500–800 parts/hour to 1,600–2,000 parts/hour
- 63% higher throughput in automated quick-set press cells vs. manual operation
- Up to 3× longer tooling life due to improved material consistency and lubrication control
- A single operator is now able to run multiple machines in select cells
- Reduced dependence on temporary labor staffing
- Improved quality control and reduced internal and customer DMRs through vision inspection
Clow, a Minnesota-based manufacturer, scaled from a single automation project to 24 integrated production cells, doubling blanking throughput and increasing press productivity by 63% in the process. What began as an effort to increase output has evolved into plant-wide automation that supports high-mix production, reduces labor dependence, and improves consistency.
Facing labor shortages and rising customer demand, Clow needed to increase throughput without sacrificing quality or flexibility. By partnering with All World Automation, formerly CNC Solutions, Clow was able to develop a scalable automation approach aligned with its production environment.
Clow Director of Manufacturing Joe Goble reports that over the past eight years, Clow’s partnership with the team at All World Automation resulted in the deployment of automated cells across blanking, quick-change stamping, and robotic welding. The initial blanking project expanded into a flexible system of robotic cells capable of supporting a wide range of part families, while reducing reliance on out-of-state staffing agencies and the associated costs of recruiting and housing temporary labor.
All World Automation engineered a semi-automated blanking cell for Clow that standardizes material handling and reduces manual labor. The system automatically loads, centers, feeds, and blanks material, then conveys scrap to a hopper to support continuous operation with minimal operator involvement
Blanking Automation Builds the Foundation
Blanking was the first process targeted for automation due to its labor intensity and variability. Manual loading, alignment, and scrap handling created inconsistent output and tied up operators on repetitive tasks.
All World Automation implemented a semi-automated blanking cell to standardize material handling and reduce manual work.
Raw strip material is loaded onto an inbound conveyor, where a gantry system lifts and positions each sheet. A centering station ensures repeatable alignment before the material enters servo-driven feed rolls, which synchronize with press strokes for continuous operation. Scrap is automatically dischargedal operator intervention
As the system proved successful, the project was replicated, and what began as a single blanking cell ultimately scaled to nine systems across the shop floor. Each iteration was engineered to accommodate wider material, thicker gauges, and a broader range of alloys.
“One of the later cells was built around a 220-ton press,” explained All World Automation Mechanical Engineer Cole Keller. “The initial projects focused on steel, where we used magnets to handle the material. As we moved to non-ferrous metals, such as aluminum and stainless steel, we switched to vacuum handling. Over time, production demands required automation to scale for larger presses, higher tonnage, and wider, thicker sheets, handling heavier loads while maintaining precision and repeatability under more challenging conditions.”
Because flexibility was a requirement across all cells, each press-feeding system incorporated hydraulic vertical adjustment to accommodate die height variation. Feed units and conveyors were positioned using low-flow hydraulic cylinders for controlled and repeatable movement. On the larger presses, packaging became more challenging due to the need for higher-capacity cylinders and more robust guide rails to handle increased tonnage, necessitating careful layout to maintain alignment and material transfer accuracy within limited space.
“These were originally just blanking presses with basic guarding,” Keller added. “Integrating automation meant fitting a lot of moving components into a small footprint while maintaining safety, accuracy, and repeatability.”
Manual blanking typically produced 500 to 800 parts per hour, while automated systems now run at 1,600 to 2,000 parts per hour, depending on part geometry and other variables. While part size and related factors influence output, the process is at least twice as fast
Guderjohn highlighted that automation also reduced the risk of mis-blanked parts associated with manual handling, improving both yield and operator safety. In addition, consistent material presentation and oil application extended tooling life significantly, with tools lasting up to three times longer before requiring sharpening or repairs compared to manual processes.
Quick-Set Automation Expands Flexibility
All World Automation integrated a FANUC M-10iD/12 robot with a flexible 10DER machine-tending platform and dual-camera vision to accurately handle varied part geometries. Quick-change EOAT enables fast tooling swaps, allowing the system to scale from 10 initial part numbers to hundreds more.
Following success in blanking, Clow expanded automation into quick-set presses used for high-mix, low-volume production with frequent changeovers.
“A quick-set press may change over six times a day,” said All World Automation Sales Manager Randy Roehl. “The challenge was switching between part numbers efficiently and without losing productivity.”
All World Automation integrated a FANUC M-10iD/12 robot with a vacuum gripper and a custom 10DER machine-tending platform featuring a four-sided infeed queue. Dual-camera machine vision ensures correct orientation and thickness. A SCHUNK manual quick-change EOAT system allows rapid tooling changeovers across hundreds of part variations.
“The initial system ran 10 part numbers, but it needed the flexibility to scale to hundreds or even thousands of variations,” said All World Automation Mechanical Engineer John Brebeck.
The result is approximately 63% higher production with automated quick-set work centers compared to manual operation, while enabling a single operator to manage multiple machines instead of a one-to-one staffing model
“Machine vision makes automating this process possible; without it, we could not place our parts with the same level of accuracy or speed. This vision will also reject anything that is not a replica of what the vision is supposed to see,” said Clow Automation Supervisor Rory Keena. “If a part is mis-blanked, or a hole is missing, or there are any other issues with part geometry, the vision and robot combination throws it out. The vision has also eliminated the ability to form the parts backwards.”
Robotic Projection Nut Welding Improves Quality Control
The fully automated robotic nut-welding cell uses vision-guided part location, precision gripping, and an integrated welder to complete the entire sequence, while operators primarily stage parts and maintain the nut feeder.
Building on these successes, Clow implemented a dedicated robotic projection nut-welding system designed for repeatability, part variation, and throughput, according to All World Automation Lead Mechanical Engineer Grant Johnson.
Parts enter the cellge detection and contrast. A FANUC iRVision system locates each bracket and applies positional offset correction before picking. The robot then transfers the part to a resistance spot welder integrated with an automated nut presenter, ensuring consistent nut placement and weld cycle timing
Custom end-of-arm tooling (EOAT) accommodates bracket sizes ranging from 1 × 2 inches to 16 × 16 inches. Vision systems also play a key role in preventing errors, identifying incorrect orientation or mis-blanked parts before they enter downstream processes.
The robotic sequence is fully automated: vision locate, pick with offset compensation, weld cycle execution, and transfer to the outbound conveyor. Operators are responsible only for staging incoming brackets and maintaining nut feeder supply, minimizing manual touchpoints while sustaining cycle time.
Designed and integrated by All World Automation, this robotic welding cell combines FANUC iRVision, custom EOAT, and automated nut presentation to deliver repeatable positioning, improved quality control, and reliable weld performance across a wide range of bracket sizes.
A FANUC M-10iD robot was selected based on reach envelope, payload capacity, and repeatability requirements. Its curved J2 arm geometry enables operation within a compact cell footprint while maintaining access to the weld station and regrip fixture. A manual quick-change EOAT interface was incorporated to support future bracket variations and reduce tooling changeover time.
The system improved both weld quality and process control. Parts are presented to the welder in a consistent orientation, while integrated checks identify missing hardware and automatically reject nonconforming components, segregating them from good parts. This ensures outgoing work-in-process remains compliant and has contributed to a reduction in both internal and customer DMRs.
“Consistency in quality was the primary goal with this system,” Keena said. “It runs at comparable speeds to a manual operation, but with far greater accuracy. The result is little to no rework and related costs.”
Results: Plant-Wide Impact
Across blanking, quick-set, and nut welding systems, Clow has increased throughput, reduced reliance on temporary labor, and strengthened process consistency.
Blanking output increased by 150–220%, rising from 500–800 parts per hour to 1,600–2,000 parts per hour, while automated quick-set press cells achieved 63% higher throughput compared to manual operation. Improved material consistency and lubrication control also extended tooling life by up to 3×, reducing wear-related downtime.
All World Automation developed a robotic projection welding system that helps reduce rework, improve part accuracy, and maintain consistent throughput with minimal operator involvement.
According to Clow President Lori Davies, automation has significantly reshaped operations, improving accuracy, minimizing errors, and enabling more efficient output, even during peak demand.
On the workforce side, it has moved employees away from repetitive tasks and into higher-value roles such as problem-solving and quality assurance, improving engagement while supporting upskilling.
“Overall, these improvements made us far more responsive to customer needs, with faster turnaround times and more reliable delivery, strengthening our competitiveness in the market,” Davies said.
