A group of people stands in a workshop setting. Some wear orange and navy work uniforms, while others are in casual light blue and white shirts. The background features industrial equipment and piping.
Case Study

Lepol Metal

A diverse group of 14 people stands inside an industrial warehouse. Some wear orange safety shirts and others wear blue dress shirts. They pose in two rows, with men and women smiling at the camera. Industrial equipment is visible in the background.

Navigating Operational Challenges

Lepol Metal, established in 1976, has been a cornerstone of support for the construction industry for over 45 years. Renowned for their exceptional service in mechanical projects for commercial construction, Lepol specializes in offsite steel manufacturing, metal work, piping systems, stainless services, prefabrication, and onsite support. Their commitment to delivering efficient, cost-effective, and high-quality customized solutions has streamlined construction processes across various industries, including commercial, industrial, and critical infrastructure.

Lepol Metal encountered significant operational challenges in their pursuit of achieving higher welding speed and consistency without compromising quality. Operating within a limited physical footprint and facing constraints on expanding their workforce, Lepol needed an innovative solution to enhance their mechanical service capabilities, particularly in pipe welding.

A person operates a large industrial welding robot in a factory setting. The machine, marked "Novarc," is positioned near metal pipes and equipment, with concrete walls and a high ceiling visible in the background.

Investment in Novarc's Spool Welding Robot

After evaluating various options, Lepol Metal chose Novarc’s Spool Welding Robot (SWR) for its compact design, ability to boost welding efficiency, and consistent delivery of high-quality welds. The SWR’s seamless integration into Lepol’s existing operations marked a transformative step toward heightened productivity and efficiency.

Quantifiable Outcomes

The integration of Novarc’s SWR has yielded a significant increase in daily welding output, substantial financial savings, and high-quality, consistent welds. It has also mitigated skilled labor shortages and enhanced operational capacity.

Increased Productivity

Before implementing the SWR, Lepol averaged between 50-60 weld inches per day. Post-implementation, they now achieve between 250-300 weld inches per day on average. “On a particularly productive day, we’ve reached up to 351 weld inches,” says Luke, Owner of Lepol Metal. This represents a 400-500% increase in daily welding output, allowing the company to complete projects in a fraction of the time previously required.

Addressing Skilled Labor Shortages

The user-friendly interface of the SWR has mitigated the impact of skilled labor shortages. Lepol employed an 18-year-old operator with no prior welding experience, who quickly mastered the SWR. This innovative approach has reduced dependency on highly skilled welders, with the SWR operator performing at levels previously unattainable by manual welding.

Close-up of a metallic pipe with a welded joint next to a circular flange. The weld has a slightly uneven texture with rainbow discoloration. The flange has several holes around its edge. The background is blurred concrete.

Enhanced Operational Capacity

The SWR has enabled Lepol to handle a higher volume of work without increasing their workforce. Approximately 75% of Lepol’s pipe welding is now completed using the SWR, significantly enhancing their operational capacity. This has allowed Lepol to undertake larger projects and complete them faster, directly contributing to increased business opportunities and revenue.

This case study exemplifies how Lepol has leveraged cutting-edge technology to set new industry standards, reinforcing their commitment to delivering high-quality, customized solutions. The successful integration of the SWR has established a new benchmark for efficiency and quality in the mechanical services industry, positioning Lepol Metal as a leader in innovation and excellence.

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