Pro-Dig: From Successful First Implementation to an Expanded Robotic Welding System
About the Customer
Pro-Dig is a U.S. manufacturer specializing in high-quality augers, drilling, and piling equipment. Well-known in the industry for engineering excellence and durable construction, the company continuously modernizes its production operations to meet growing demand and support customers across construction, utilities, and infrastructure sectors.
Customer Challenge
After successfully operating their first robotic welding cell powered by Abagy for over a year, Pro-Dig faced increasing production demand and a growing volume of large batch orders. Their existing setup could no longer support the required output consistently, even when operating in two shifts.
To expand capacity and maintain product quality, Pro-Dig evaluated options for scaling their welding operations. The goal was to:
To expand capacity and maintain product quality, Pro-Dig evaluated options for scaling their welding operations. The goal was to:
- Increase throughput without adding manual welders
- Maintain consistent weld quality across all auger types
- Support predictable production planning
- Reduce labor-related constraints across shifts
The Decision
Based on the performance of the first Abagy-enabled cell, Pro-Dig chose to extend their automation footprint with a second, larger robotic welding system equipped with Abagy’s adaptive, machine-vision-based software.
The decision was driven by three main factors:
The decision was driven by three main factors:
- Proven stability and ease of use of the initial system
- Need for higher throughput and parallel processing
- Desire to minimize labor dependency while scaling production
The Solution
Pro-Dig’s new robotic welding setup includes:
- Yaskawa robot on a track for extended reach
- Four work zones, allowing two augers to be welded simultaneously while two more are being prepared
- Two positioners for optimal welding orientation
- Miller welding source
- Abagy adaptive welding software, enabling automatic trajectory generation without manual programming—even for varied auger geometries
Application
The robotic cell is used for welding drilling and piling augers of different diameters and configurations. The combination of multiple work zones and adaptive software allows Pro-Dig to run an efficient, high-mix production environment without the need for robot programmers or fixed tooling.
“
Our customers are now placing orders in large batches, and there are times when the demand exceeds the capabilities of our current setup, even when running two shifts
— Greg Pierson, Chief Design Engineer at Pro-Dig
— Greg Pierson, Chief Design Engineer at Pro-Dig
Outcome
- Significantly increased production capacity
- Stable, repeatable weld quality across shifts
- Ability to weld two augers in parallel
- Reduced labor dependency and fewer production bottlenecks
- Scalable automation architecture supporting long-term growth
Summary
Pro-Dig’s expansion from one to two Abagy-enabled welding cells demonstrates how scalable, adaptive robotic welding can support growing production needs. By integrating machine-vision-based automation, the company strengthened throughput, improved consistency, and created a reliable foundation for continued business growth.