Over the past few years, there have been several news updates from WELDCOA about investments made at their facility, as well as additions to their team. Last September, I had the opportunity to travel to Aurora, IL to see it all firsthand.
Since this was my second visit, (my first since 2017) I had an idea of what to expect, but when I got there it was like a completely different place seeing all the upgrades. I couldn’t help but imagine the amount of work and planning that must have gone into researching the equipment needed and how to best utilize the space.
Automated Manufacturing Processes
With half of WELDCOA’s business being fill plant design/build and the other half being welded products, each machine and robot is complementary to the complete picture. The overall business model of WELDCOA is to design and build the fill plant as a generational investment for a distributor/end-user and then to offer accessories and material handling components that will be needed for daily operational efficiency to fill and deliver the cylinders to customers. The welded products, such as cradles, pallets, and truck bodies, ensure future business, as distributors grow to need more of these assets over time.
There were huge heavy-duty machines and robots moving steel like it weighed nothing. Truck bodies, trailers, pallets, cradles, manifolds all get mass produced by a combination of humans and robots. One recent investment is a machine that feeds and cuts sheets of steel, completely utilizing each sheet of steel. One sheet could have a piece of the fill plant system, piece of pallet, and part of the gas pack. Once cut, the pieces are separated for assembly. This surely helps WELDCOA maximize their raw material.
Other automated systems include one that is making the truck bodies and another making the pallets. The truck body process is almost completely automated with a machine holding and flipping the metal, while a robot welds them together in programmed motion. The pallet station is similar, with a machine moving the metal, while a robotic welder is doing most of the welding. After the automated welding, each product is inspected to make sure the weld is accurate and complete.
Automation has become a common theme both in WELDCOA’s manufacturing processes and in what they preach to distributors pursuing the latest technology in gas filling and transportation.
Added Staff to Support Growth at WELDCOA
Automation can sometimes mean reduced staffing. Not in this case. WELDCOA has redeployed existing staff, plus added more people to help scale their business. Adding positions like technical sales along with other on-site experts has allowed them to be in more places at one time. Since each project has its own unique challenges, the added staff helps plan and execute each job more effectively. Now, more than ever, distributors and end-users need unique solutions for so many different types of gases that the added personnel has helped them master their craft. From industrial gas to specialty gases, WELDCOA has a wide range of experience when it comes to filling cylinders and moving molecules.
A point of pride for owner, Hector Villarreal, WELDCOA has two of his children in the business in different roles. His daughter, Valerie, joined the Marketing team reporting to Director of Marketing, Melissa Heard, bringing video and other Marketing talent in-house. On the production side, Logan, Hector’s son, reports to Operations Manager Dan Calabrese working on the production line as part of the team assembling their high quality products.
Hector emphasizes that his expectations of his two children are no different than any other employee at WELDCOA. Neither of them reports directly to him, allowing him to watch from a distance as they grow and mature in their young careers.
WELDCOA Innovation Center (WIC)
A key to their success is the WELDCOA Innovation Center which is a fully operational fill plant on-site where they host live, in-person training for both their employees as well as distributor employees who need the technical expertise of how to fill cylinders safely. Hosting these classes for customers has allowed them to stay ahead of the curve, giving them direct feedback on what types of challenges their customers are facing in their operations. It’s also a natural forum for them to develop new technology as they see a need arise through these training classes.
WELDCOA Invests in Relationships
Investments are a common theme within WELDCOA. These investments extend beyond monetary investments in equipment and training. But at WELDCOA, they truly invest in their relationships, as well. One of the things that I admire most about WELDCOA is how they go big on industry hospitality and bringing many their staff members with them to GAWDA and other industry events. Whether it’s hosting 40-50 people at a Phillies game or covering the bill for a large group of customers and business partners to eat out, WELDCOA understands that this is a people-first industry. These gestures show their commitment to growing and developing relationships, ultimately building trust and understanding over time. Top to bottom WELDCOA’s organization is filled with genuine people with a help first mindset. And that generosity extended to their hospitality during my visit. Thank you to WELDCOA for your continued partnership and support!
Check out this one-on-one interview with Hector as he talks about what it means to him to work alongside his children at WELDCOA.
