Easy Access Co case study

Elevating Production with Robot Welding.

Background

Easy Access Co. manufactures aluminium scaffolding systems, mobile scaffolds, and height access equipment from its facility in Maungaturoto, Northland. With a focus on safety, performance, and continuous improvement, the business has grown to become one of New Zealand’s leading suppliers to the construction, trades, and hire industries.

As product demand increased, Easy Access Co. began looking at new ways to improve welding throughput and take weld quality to the next level across its access equipment range.

Project Overview

Customer: Easy Access Co.
Product: Aluminium Scaffold Components
Country: Maungaturoto, New Zealand
Installed: 2020
Industry: Access Equipment Manufacturing
Solution: S-4800 Robot Welding Cell
Featured Equipment: OTC FD-B6L Long Through Arm Welding Robot, OTC FD19 Controller + Teach Pendant, OTC P500L Power Source + 500A Water Cooled Torch, OTC Positioner Headstocks 1PC500, OTC Synchro-feed Welding System, Autoa Servo Controlled Slider 6000mm Travel, Integrated Safety Componentry.

The Solution

To support growing production demands and improve welding performance across its access equipment, Easy Access Co. partnered with Autoa to implement an S-4800 robotic welding cell.

The cell was configured to suit their product sizes and workflow, with a 6000mm servo-controlled slider enabling the robot to move freely along larger components. Dual OTC positioners provide flexible part handling and ensure optimum weld angles across a range of assemblies.

The system is powered by an OTC FD-B6L long through arm robot, paired with an FD19 controller and Welbee P500L welding source. It also includes a 500A water-cooled torch and OTC’s Synchro-feed welding system, giving the team finer control over weld quality and helping achieve faster, cleaner results on aluminium assemblies.

The Results

Integrating Autoa’s robotic welding cell significantly improved Easy Access Co.’s production process, increasing output and reducing reliance on manual welding. A key breakthrough was the ability to reliably weld thin-walled aluminium with a thickness of 1.2–1.6mm, which marked a major step forward in their manufacturing capability.

Tasks that once demanded considerable hands-on time are now completed more efficiently, enabling the team to manage a higher workload across core product lines. The robotic cell also reduced weld cycle times and rework while improving overall quality and consistency.

The IMPACT ON Easy Access Co’S BUSINESS

The investment in robotic welding has improved how Easy Access Co. manufactures its aluminium access products. The S-4800 cell has added stability to the production process, with consistent weld quality, helping the team meet growing demand without compromising on standards.

With skilled staff now able to focus on complex fabrication and assembly work, the business is operating more efficiently across the board. The shift to robotic welding has not only increased productivity but also reinforced Easy Access Co.’s commitment to continuous improvement in manufacturing.

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.