A new Inspect and Pack Robotic Cell is now operating at Welder 7 inside ODM Tool & Manufacturing’s Chicago-area facility. The addition expands automated inspection and packing capability and strengthens post-weld quality control for high-volume programs.
For 80 years, ODM Tool & Manufacturing has grown by making steady, practical investments in its operations. Three generations currently lead the company, and a fourth generation works inside the business. Long-term thinking drives decisions on equipment and process improvements. The new cobot reflects that same mindset: add capability where it solves a real production challenge and protects customer requirements.
Why ODM Added the Robotic Cell
Post-weld inspection support and packing required two operators to manage manual handling and sorting. The line performed well, yet labor dependency and small fluctuations in cycle time limited how stable the output could be across shifts.
Engineering and operations teams evaluated that stage of production carefully. Increasing throughput per operator became a priority; reducing repetitive manual sorting was another. Strengthening quality control at the same time mattered just as much.
Installation of the Inspect and Pack Robotic Cell addressed all three.
Today, one operator works in coordination with the robotic system. Direct labor tied to post-weld inspection and packing has been reduced by an estimated 50 percent. That improvement came without disrupting upstream welding or altering customer specifications.
Where the Cobot Operates
The robotic cell sits directly downstream of our Welders. Placement allows welded components to move straight into the next stage of processing without delay.
After welding, the operator loads the part onto a fixture. From there, the robot performs automated transfer and presentation. A dedicated vision-based poka-yoke system evaluates the part and determines its disposition. Based on that inspection result, the robot executes automated defect separation and routes components accordingly before final packing.
Manual sorting and repositioning once required constant attention. That portion of the workflow now runs through a consistent, repeatable sequence.
Robotic welding support operations upstream remain unchanged. Integration occurs at the post-weld stage, strengthening the overall flow rather than replacing it.
New Capability: Automated Post-Weld Handling and Sorting
Prior to installation, handling, inspection support, sorting, and packing were manual tasks. Throughput depended on operator availability and pace. Fatigue could influence timing late in a shift, and small pauses accumulated.
The Inspect and Pack Robotic Cell introduces automated post-weld handling that did not previously exist at ODM Tool & Manufacturing. Coordination with vision-based inspection enables clear separation of conforming and non-conforming parts. Sorting happens immediately, based on validated inspection data rather than manual judgment.
Repeatability is the key advantage. The robot presents parts the same way every cycle. Handling remains consistent regardless of shift. Automated defect separation reduces the chance of mixed inventory and minimizes rework risk.
Cycle times have become more predictable and micro-stoppages tied to manual repositioning have been reduced. Supervisors now see steadier parts-per-hour output, which supports long-term scheduling and open capacity planning.
Early Impact on Throughput and Labor
Labor reduction was the first visible change. Moving from two operators to one operator supported by automation cut direct labor hours for post-weld inspection and packing roughly in half on the 30-5949 program.
Beyond that measurable shift, the flow itself feels different. Parts move from weld to inspection support to packing with fewer interruptions. Operators oversee the cell rather than managing repetitive sorting motions. Production holds a more consistent rhythm throughout the day.
High-volume welded components benefit most from that stability. Programs requiring vision-based inspection and precise separation of conforming and non-conforming parts gain clear advantages when manual variability is removed from the equation.
What Customers Will Notice
Visitors touring the facility will see a controlled post-weld environment built around repeatable automation. Parts are transferred, presented, sorted, and packed through a coordinated system that strengthens quality control.
Inspection decisions remain grounded in vision-based poka-yoke technology, while the robot handles the physical execution. This combination protects part integrity while maintaining steady output.
Delivery reliability improves when throughput remains stable across shifts. Risk of mixed or non-conforming parts decreases when sorting is automated. Customers who depend on just-in-time schedules benefit from a process that supports consistent production without additional labor volatility.
Continuous Improvement at ODM Tool & Manufacturing
Senior Manufacturing Engineer Jose Lopez led the implementation of the Inspect and Pack Robotic Cell, with support from Manufacturing Engineer Nicholas Francis and the maintenance team. The system was integrated into the existing workflow through close coordination between engineering and maintenance.
Continuous improvement at ODM Tool & Manufacturing centers on removing waste, strengthening reliability, and supporting the people who run the operation. Automation is added where it improves performance and reduces repetitive manual strain. Process control replaces manual sorting where consistency matters most.
The new cobot represents expanded automated inspection and packing capability, stronger support for robotic welding operations, and measurable labor efficiency gains. Investments like this allow ODM Tool & Manufacturing to produce more parts with fewer labor hours while maintaining strict quality standards.
Manufacturers evaluating high-volume welded programs can see that commitment firsthand. Connect with the team at ODM Tool & Manufacturing to learn how automated inspection and packing can support your next stamping and welding program.
