Innovation drives WeatherTech's business success

At WeatherTech, more thought and technology goes into creating car mats than its competitors. Its extensive and innovative product offerings highlight its industry leadership, but more interesting is how WeatherTech creates its catalog. What is the secret of success worth knowing? How can other manufacturers use WeatherTech’s expertise to inspire new technology and automation?

Who is WeatherTech?

Manufacturing giant WeatherTech calls Bolingbrook, Illinois home, where it makes its famous WeatherTech mats. Its manufacturing operations embrace the future by integrating modern technology at incredible levels. At the same time, it increases the value of its workforce and the quality of its products.

WeatherTech is proud to be American-powered and cherish the value of American workers and domestically sourced materials. A company feels warmer when the employees developing their skills and working with the products are more local. They make a multitude of objects, including:

• Interior and exterior protection of the vehicle
• Hands-free accessories for tablets and phones
• Home tools like under-the-sink mats and soap savers
• Germ protection accessories
• Pet products, like feeders and car protectors
• Golf Cart Products

WeatherTech offers countless models to ensure product compatibility with every vehicle, and manufacturing for everyone, including Kia and Volkswagen. The manufacturing cycle is an amazing insight into the future of production and the quality of items buyers can expect. Its product line is broad in scope, but there is one common thread: automation.

What technologies power WeatherTech?

WeatherTech strives to manufacture products for all OEMs, but how can it mass-produce quality products with precision if some vehicles are newer, older, or rarer than others? The answer lies in data.

Analysts use reverse engineering to uncover the most essential secrets of what a vehicle is made of, preventing engineers from having a fixed mindset about product design. The facility offers education to everyone, across all disciplines, including educators and scientists, as they look to this type of manufacturing for their future training.

Automation engineers and machinists are leading the way in implementing intelligent robotics. Employing specialists with modern automated machines and life cycle management qualifications helps the company move to an even more advanced setup. Staff collect as much information as possible about the machines to find ways to integrate other technologies more seamlessly.

Remember that not all technology has to be electronic. WeatherTech leverages several types of technologies to get the most out of its products, including:

• ISO9001 standards
• Computer Aided Design Software
• Procedural documentation software
• Computer Aided Manufacturing Software
• Stereolithography, also called 3D printing
• CNC machines
• Thermoplastic elastomer material
• WeatherTech patented high-density tri-extruded material
• Thermoforming
• 6-axis robots

The combination of these assets makes the production so unique. The materials WeatherTech uses allow products to be fully recyclable – a priority that other companies often avoid due to additional costs. However, the absence of materials like lead and latex makes the process easier, especially thanks to its automated setup.

How is WeatherTech innovating in the industry?

Any good manufacturing company has a balance between manual and automatic research and development. WeatherTech uses tools that scan vehicle floors to obtain data and a map. Development teams translate their results, such as measurements and adjustments for different car types, into raw data for processing. No measuring tape is needed.

Then we move on to the design stage. The data feeds the software to write the most perfect rug designs a program can come up with. Designers use these templates for freeform modeling to detail accuracy and style. No need to waste raw materials creating countless versions before the finished product: engineers and designers can view and run mock tests on digital models before sending files to production.

All it needs is a seal of approval. Then, specialized machinists supervise and operate the automated machines that forge the metal mold. Machines and other assistants – like SCARA robotic arms – use cutting-edge technology to press and cut designs. The finished product uses ovens that rotate and shape the molds on a frame, ensuring a perfect stamp every time.

However, not only the manufacturing process is automated. Like it’s straight out of a sci-fi movie, state-of-the-art automated guided vehicles (AGVs) power warehouses for efficient and safe storage without human assistance. It allows employees to move into more relevant and valuable roles, where they can learn robotic operations and database management, while AGVs and other robotic assistants catalog warehouses to perform at their peak. shape.

How will this manufacturing model develop in the future?

Many steps in WeatherTech’s manufacturing process can happen while the manager sleeps, but what if it could all happen remotely? Hyper-automation is the next phase of tech-savvy businesses, maximizing the intellectual capabilities of the workforce for creativity, communications and quality assurance – just let robots do the rest. Conversely, machines could dock and print prototypes without a single second of human intervention.

An effort like this would require investing in tech startups or in-house product development.

Seeking outside ideas is not an option when WeatherTech does not tolerate imported piping in construction. So every advance in automation within its walls must be self-derived, which could inspire other domestic companies to do the same to keep America a front-runner in Industry 4.0.

The company is already leveraging everything it can from automation and data, leading many experts to wonder how it plans to use AI and machine learning to improve its processes. It’s possible, but not confirmed.

However, WeatherTech has embraced the possibilities of AI as its interest in cars has carried over into the esports phenomenon of competitive iRacing. WeatherTech-sponsored events have met the world of digital racing, as AI helps drivers train for events around the world instead of relying on human competitors to test their skills. Such collaborations may not fall within WeatherTech’s manufacturing walls, but a little outside-the-box thinking never hurt anyone in the pursuit of new avenues of innovation.

WeatherTech as a Competitor in the Automation Market

The way WeatherTech makes accessories for cars and homes might amaze anyone. Additionally, it demonstrates the versatility of modern manufacturing and automation technologies to organizations around the world. Its reputation is due to its commitment to optimizing production. It pushed all electronic devices to their limits.

Ultimately, this design will become the standard for every industry and operation, leaving the companies that have led the way – like WeatherTech – empowered to never stop dreaming bigger.