Maintenance of automated installations, with or without a robot.
Robots, controllers, vision and safety systems. Any make, and whoever installed them.
Line stopped? +34 94 676 63 86 inser-services@inser-robotica.com
When a cell stops, it is not a machine that stops: it is the whole line.
An automated line concentrates in one point the work that several people used to share. That is what makes it pay, and it is also what makes a stoppage so noticeable. Which is why commissioning is not the end of the project: it is the moment when it starts to really matter that somebody knows that installation.
Inser Services is our technical assistance division, and it has been here as long as the company has. It maintains installations delivered since 1987 —robots and controllers of different makes, generations and conditions— and also automated lines with no robot at all that we did not build.
If it is automated and it stops your production when it fails, it is ours.
Plenty of people call us assuming we only touch robots. We do not, and never did: what we maintain is the whole installation, with or without a robot.
Robotic cells
Any make, any age, any condition, whether we built them or not.
Controllers and control systems
PLCs, panels, drives, communications and the programming that governs it all.
Conveying lines
Conveyors, lifts, diverters and accumulation: whatever moves the material between machines.
Machine vision
Inspection and guidance cameras, and the tuning they need when the product changes.
Machine safety
Fencing, interlocks, scanners and light curtains. The part that can never fail.
Mobile robotics
AMRs and autonomous transport inside the plant, with their navigation and fleet management.
Pneumatics and hydraulics
Grippers, actuators, filters and everything that wears out without warning.
Monitoring
The INSER-IoT platform on a line that is already automated, with or without a robot.
You are looking at cells that have been producing for years. Someone keeps them that way.
None of these installations is a demonstration. They are our projects in customers’ plants, and what you see in each video has a maintenance plan behind it, a committed response time and someone who knows that installation inside out. This is what wears in each of them, and what we do to keep it running.
01 Welding and joining
Maintenance of robotic welding and riveting cells
In a welding cell what wears out is not the robot: it is everything that touches the part. The torch, the consumables, the tool centre point calibration, the positioner turning under the weld. A TCP two tenths out does not stop the line —it would be easier if it did—: it turns out parts that need reworking, and that shows up in rework long before it shows up on a maintenance report.
- Torch and consumables
- TCP calibration
- Positioner and turning table
- Wire feed system
- Fume extraction
02 Handling and end of line
Maintenance of palletising and end-of-line robots
It is the stretch that racks up the most cycles in the whole plant and the one that stops it most often. A gripper makes tens of thousands of picks a month; the vacuum circuit loses flow little by little and nobody notices until a pallet falls. Here preventive maintenance needs no argument: it pays for itself, in stoppages that never happen.
- Grippers, clamps and suction cups
- Vacuum circuit
- Gearboxes, belts and lubrication
- Conveying and accumulation
- Strapper and wrapper
03 Machine vision
Maintenance of machine vision and bin picking systems
A camera almost never breaks down. What changes is everything else: the lighting ages, the product changes its sheen or its packaging, a new item comes in, and the same program that worked for two years stops finding the part. Maintaining vision is mostly recalibrating and registering what did not exist when it was installed, and most of the time that is done remotely.
- Camera calibration
- Lighting and optics
- Registering new products
- Location models
- Protection in dirty environments
04 Mobile robotics
Maintenance of AGVs and AMRs on site
A mobile robot has no fixed place, so neither does its maintenance. Batteries, drive, safety scanners and, above all, the map: every time a rack moves or an aisle changes, the whole fleet has to be told. It is the equipment most often maintained without anyone laying a hand on it.
- Batteries and charging stations
- Scanners and safety fields
- Map and navigation
- Fleet traffic management
- Wheels and drive
05 Order picking
Maintenance of picking and order-building cells
Here what fails is rarely mechanical. It is the conversation between your management system and the cell: an order with a format nobody planned for, an item nobody registered, a mixed pallet that stops adding up. Maintaining these installations is, above all, keeping the software alive, and that takes knowing the installation and not just the robot.
- Integration with your ERP or WMS
- Registering formats and products
- Mixed palletising rules
- Traceability and records
- Control updates
Two questions to work out how we can help.
It is not a form and nothing gets sent. It is there so as not to waste your time: if yours is a today problem, what you need is a phone number; if it is six months away, what you need is for us to listen properly.
Nine services on the same installation.
The usual route is to start with an audit and then decide, with data, what is actually needed.
Preventive maintenance
Planned inspections of robots, controllers, pneumatics, safety devices and wearing parts, with the calendar set around your shutdowns and not ours. The breakdown that does not happen is the cheapest of all.
Assistance and emergencies
When the cell stops, the whole line stops. Immediate diagnosis, remotely first and on site if needed, with spares for the makes we integrate.
SICOR remote connection
Our remote connection tool comes with every installation: it allows the programming of robots and controllers to be seen, diagnosed and changed with no travel and no waiting.
Retrofit and upgrade
A ten-year-old installation is not thrown away: it is brought up to date. A new controller, new products, more throughput, or mobile robotics added to what is already there.
Training for your team
So your people can handle the day-to-day without calling us. We would rather you called us about the important things, not to replace a fuse.
Installation audit
A review of an existing line —whether we built it or not— to find out what is really holding it back and what is worth touching.
Robot repair and replacement
Repair as authorised service centre for the makes we are authorised for, and replacement when the robot has passed the service life its manufacturer states and repairing it stops adding up. We tell you which of the two it is, even when the answer is the cheap one.
Programming
For robots and controllers of the most widespread makes, to improve or change how they work today. It does not have to have been built by us, nor be recent.
Monitoring
The INSER-IoT platform on a line that is already automated, to see what it does when nobody is watching. What is not measured does not improve, and in a plant what is not measured cannot be defended in a committee either.
Maintenance means getting ahead of the call.
Most of what Inser Services does happens before there is a problem, and almost none of it can be seen from the office.
Grease analysis
A sample from the gearbox says how much life it has left before production notices. It is the cheapest check there is and almost nobody does it.
Control panels
Drives, safety devices and wiring. This is where a good share of the stoppages logged on the floor as «the robot stopped» actually begin.
Training
So your team handles the day-to-day without depending on anyone. We would rather you called us about what really deserves it.
Monitoring
Knowing what the line does when nobody is watching. What is not measured does not improve, and cannot be defended in an investment committee either.
Connected to your cell, wherever the plant is.
SICOR is the remote connection tool we developed ourselves, and it comes with every installation of ours. It allows the state of the system to be seen, the incident to be diagnosed and the programming of robots and controllers to be changed there and then.
Three out of four incidents are resolved this way, with nobody travelling. It is also why a plant in Bizkaia and a plant in São Paulo get the same service.
What sits behind a resolved incident.
Just over a minute: the team, the remote connection, and how an incident gets resolved without the plant waiting for anyone to arrive.
Brochure
Inser Services, in four pages
The maintenance brochure, all of it, with nothing to download. Open it the way you open paper.
Drag the page, or use the arrow keys.
There are two manufacturers who let us open their robots. That is theirs to grant.
An authorised service centre is not the same as an integrator, and almost nobody makes the distinction. The first is granted by the manufacturer after training you and watching you work; the second means we build it and program it, which is true of all eight.
Authorised service partner
Authorised service partner since before the brand opened its European base in Neuss. Programming and repairing their robots without a break ever since.
Authorised service partner
Authorised service partner, going back just as far. We use it mainly for welding: the TAWERS series builds arm and welding power source into a single machine, and nobody else does that.
And we also install and programme:
+1,000
75 %
We serve wherever the installations are, not wherever suits us.
Every dot is an area with work of ours, and the installations we maintain are not only the ones we built.
All the documentation for your installation, in one place and always the latest version.
The drawings, diagrams and manuals of an installation end up spread between an email from four years ago, a shared folder and the drawer of someone who has left. The day a wiring diagram is needed is always the worst day to go looking for it.
- 01Robot and its reach
- 02Infeed conveyor
- 03Pallet positions
- 04Safety scanner
- 05Interlocked access gate
- 06Perimeter fencing
- Technical documentationDrawings, electrical and pneumatic diagrams, spare parts lists and manuals, each at its latest revision.
- A wiki for your installationWhat has been learnt about your particular line: the settings, the knacks and what happened once before.
- IncidentsWhat is open, what was done last time and who is handling it.
- Orders and sparesThe status of what has been ordered and which parts are critical for your installation.
- InvoicesYours, downloadable, without asking for them by email.
- Maintenance historyEvery visit, with its date. Useful for an audit and for defending an investment.
It is not open yet. We are building it with customers who have already told us what they need to hand, and that list is what decides.
Eight answers before you have to call and ask for them.
Do you maintain installations you did not build?
Yes, and it is a large part of what we do. The make of the robot or controller, the age of the installation and who built it make no difference. The first step in that case is an audit, because an installation has to be known before anyone commits to maintaining it.
And if my line has no robot at all?
That too. Conveyors, controllers, panels, vision, safety devices and pneumatics are just as much an automated installation as a cell, and they stop production just as effectively when they fail. What we maintain is the line, not the robot.
What does being an authorised service centre mean?
That the manufacturer has trained us, watched us work and authorises us to repair its robots. You do not apply for it: they grant it. We are one for Kawasaki and for Panasonic. For the other makes we are integrators, which means we build and program them.
How is a breakdown handled?
Three out of four incidents are resolved without leaving Inser, through a remote connection.
Does production have to stop for preventive maintenance?
The calendar fits around your shutdowns, not ours. A good share of the inspections are done during planned stops, at shift changeover or in the summer shutdown, and that is decided with you.
I have a very old robot. Repair or replace?
It depends on what its manufacturer says about service life and on what keeping it running another year costs. We tell you which of the two adds up even when the answer is the cheap one, and if it is repair, we repair it.
Do you provide service outside Spain?
Yes. The remote connection comes with every installation of ours and resolves most incidents with nobody travelling, so distance stops deciding when the line produces again. For what has to be done on site, it gets planned.
What does maintenance cost?
It depends on how many machines are included, how critical each line is and what response time you need. What does not vary is the starting point: first we look at what is installed, and the proposal is built on that. Without that step, any figure is made up.
Think better automation
- Wider vision Look at the whole plant before touching a machine. What slows a line down is almost never where it hurts.
- Right decisions Decide with data: emulating, measuring and putting the numbers on the table before buying anything.
- Higher efficiency More uptime, better quality and processes that hold. Efficiency follows from them.
Do you have an installation stopped, or one that worries you?
If it is urgent, call: +34 94 676 63 86, or write to inser-services@inser-robotica.com. If what you want is to stop having emergencies, tell us what you have installed and we will look at it.
Technical serviceinser-services@inser-robotica.comInser Services
