Improving quality, throughput and uptime with Premier Automation
In modern manufacturing, welding needs to be consistent, repeatable and fast, while still meeting demanding quality standards. For many businesses, manual welding struggles to keep pace with production targets, labour availability, and the need for traceable, uniform results. That’s where Robot & Welding System Solutions come in, providing controlled processes, higher throughput, improved safety, and the flexibility to handle product changes without compromising quality.
Premier Automation designs and builds new robot systems, integrates used robots, and modifies or updates existing automated systems to meet customers’ process requirements and payback criteria. Founded in 2000, we’ve developed into one of the UK’s leading suppliers of robot-based automation and control systems, operating from our facility in Bedford with strong transport links to most parts of the country. We’re known for honest, unbiased advice, a detail-led engineering approach, and strong partnerships that support projects from concept through to after-sales support.
Robot & Welding System Solutions for consistent weld quality and repeatable output
Welding is still one of the most common applications for industrial robots because it benefits hugely from repeatability. Robot & Welding System Solutions allow you to control travel speed, torch angle, path accuracy and process timing in ways that are extremely difficult to maintain consistently by hand across long shifts. For manufacturers, that can translate into fewer defects, less rework, and more predictable output across batches.
Robotic welding also improves process consistency when products vary slightly, as robots can be programmed to follow the same path precisely every time, and systems can be designed to accommodate tolerances through fixtures, sensing, or refined tooling. Whether you’re welding fabricated frames, assemblies, brackets, enclosures, or repeat components, the ability to standardise the process can deliver measurable quality gains.
Premier Automation has experience of integrating a wide range of robot models from the world’s leading manufacturers within diverse applications. That integration expertise matters in welding because the robot is only one piece of the system. The wider cell design, guarding, fixtures, peripheral equipment and controls all need to work together to produce consistent results safely and efficiently.
Robot & Welding System Solutions designed around your process and payback
No two welding environments are the same. Material types, joint designs, volumes, takt times, available floor space, and upstream and downstream handling all influence the best automation approach. Robot & Welding System Solutions should therefore be designed around your commercial and technical criteria, not forced into a standard template.
Premier Automation aims to provide cost effective solutions that meet customer requirements, and we’ll always guide you to the most appropriate solution. Automation cannot solve every problem, and it is not suitable for every application, which is exactly why unbiased advice matters at the start of a project.
In practice, an effective welding solution often begins with a site visit and a detailed discussion around:
- Current cycle times, output targets and quality issues
- Part presentation, fixturing requirements and tolerance control
- Changeover needs and likely product evolution
- Safety requirements and operator interaction
- Integration needs for material handling, tracking or inspection
- Payback criteria and total cost of ownership
From there, the engineering work can progress into cell layout, tooling design, control strategy, and programming approach, ensuring the final installation is robust, reliable and commercially sensible.
Robot & Welding System Solutions powered by strong controls and integration
The control system is at the heart of automation, and with welding cells it is especially important. Robot & Welding System Solutions must provide an intuitive interface, clear fault finding, safe operation, and reliable communication between the robot, weld equipment, sensors and any conveyors or handling equipment.
Premier Automation specialises in designing and manufacturing new control systems for a wide range of industrial applications, including robots, special purpose machinery and process lines. We are proud to be a Siemens Solution Partner, and our design is executed in the latest Eplan platform. We can deliver full schematics, parts lists, panel layouts, cable schedules, EN13849 safety reports and controls risk assessments, supporting both compliance and long-term maintainability.
All panel build is carried out internally by fully qualified electricians, with all control panels fully tested in our workshop prior to despatch and compliant with relevant British and European standards and directives. On site, our controls electricians wire and connect the system, test power supplies and inputs/outputs, then our software engineers install and commission the control software and provide any required training.
This end-to-end capability reduces project risk because the same team that designs the system is responsible for building and commissioning it, ensuring accountability and smoother delivery.
Robot & Welding System Solutions that can be upgraded, re-engineered or relocated
Manufacturing environments evolve. Production volumes change, parts change, and factories reconfigure. That’s why Robot & Welding System Solutions should not be treated as “one and done”. They need to be maintainable and adaptable over time.
Premier Automation offers a comprehensive range of services for customers who wish to upgrade or re-engineer existing systems, or relocate automation to another site. If you’re considering modifying, upgrading or relocating an existing robot system, the first stage is a site survey visit. We assess all elements of the system and discuss requirements in detail.
Upgrades may be needed because a system has become inefficient over years of use, key elements require replacement to regain performance, throughput requirements have increased, or a new product needs to be accommodated. In many cases, reusing an existing robot in a new cell can be a cost-effective approach, provided it is engineered properly.
Relocation can also be a major win when businesses move sites or reorganise production areas. It is not always straightforward, but with experience, it can be made swift and risk-free. Premier Automation can relocate systems within an existing facility, to another UK location, or internationally if required.
Our in-house machining and fabrication facilities further support this flexibility. We can design and machine tooling parts quickly, fabricate robot pedestals and support frames, produce guarding and spreader plates, and support assembly and wiring through our experienced mechanical engineers and electricians.
Programming, offline development and digital twin for faster commissioning
Welding cells need strong programming to deliver stable cycle times and consistent quality. Premier Automation provides robot and PLC programming support across a comprehensive range of systems, from modifications to existing programmes through to Industry 4.0 digital twin development. We use tools such as Robot Studio and Siemens PLC Sim to create and edit programmes offline, which helps minimise downtime during installation and changeovers.
Off-line programming can be used to optimise cell design before manufacture and refine motion paths, reach, clearance and cycle time early. It can also be used to re-programme working cells without shutting down production, improving return on investment and reducing disruption.
On site, our programmers can improve system performance, accommodate new products, and support robots integrated by other companies as well as our own installations.
Choosing Premier Automation for robotic welding
Robotic welding delivers the best results when it is engineered as a complete solution: the right robot and process equipment, the right fixtures and guarding, the right control system, and the right programming and support. Premier Automation has established a reputation for excellence in robot integration, and we welcome the opportunity to share our experience and expertise to identify the right solution to your production problems.
If you’re exploring Robot & Welding System Solutions, talk to Premier Automation about your goals, constraints and payback criteria. We’ll help you plan a robust, reliable system that improves productivity, increases quality, and supports long-term manufacturing success.
