Tru-Bilt Industries Case Study

Strengthening Safety Bollard Manufacturing With Robotic Welding.

Background

Tru-Bilt Industries is a Dunedin-based manufacturer producing safety bollards, barriers, and impact protection systems used across commercial and industrial sites. Growing demand for their steel safety products created pressure on manual welding capacity. To support higher output in their bollard manufacturing line without adding labour, the team began exploring robotic welding as a way to increase consistency and streamline production.

Project Overview

Customer: Tru-Bilt Industries
Product: Safety bollards
Country: Dunedin, New Zealand
Installed: 2025
Industry: Safety products manufacturing
Solution: C-2000 robot welding cell
Featured Equipment: OTC FDB6L Long Reach Welding Robot, FD-19 Robot Controller + Teach Pendant, OTC P502L Power Source, RTW5000H-10 Water Cooled Torch, OTC1PC500 Headstock Positioner, Integrated Safety Componentry.

The Solution

Autoa supplied a C-2000 robotic welding cell configured specifically for Tru-Bilt’s steel safety bollards, working with Tru-Bilt to configure a custom robot welding cell that matched their part requirements, tooling needs, and bollard manufacturing workflow.

The C-2000 provides an enclosed welding station with a powered positioner and a compact footprint for medium-scale fabrication. Autoa completed the full setup, including jig design, robot programming, weld optimisation, and factory testing before delivery.

Once installed in Dunedin, the cell was commissioned and tested on site, with operator training provided to ensure Tru-Bilt’s team were confident running production from day one.

The Results

Since installing the C-2000 robotic welding cell, Tru-Bilt has seen stronger consistency across their bollard manufacturing process. Weld quality is now uniform from part to part, with consistent penetration and repeatable positioning that reduces variation between operators.

Cycle times have stabilised, giving the team predictable throughput for both small batches and larger production runs. The robot now manages the welding work, allowing operators to focus on preparation and downstream tasks.

The ability to load and unload while the robot completes the weld cycle has reduced idle time and improved overall workflow. This has helped Tru-Bilt keep production moving steadily without interruptions or delays.

The IMPACT ON Tru-Bilt’S BUSINESS

The C-2000 robotic welding cell has strengthened Tru-Bilt’s ability to scale their bollard manufacturing operations. Production capacity has increased without the need for additional welding labour, giving the team more flexibility in planning and resourcing.

Greater consistency across each welded bollard has reduced rework and helped streamline downstream processes. The predictable cycle times have also made scheduling easier, allowing Tru-Bilt to plan production with more confidence.

With a configured robotic welding cell now established in their workflow, Tru-Bilt has a clear platform for future automation. The performance of the C-2000 provides a solid base to scale capacity as production needs expand.

Talk to us about connecting your robot welding cell with Autoa remote monitoring software. Gain live visibility, direct technical support, and fewer production interruptions with software that keeps your welding operations performing at their best.