In the past it was found that when spot welding guns were replaced a significant point shift occurred. Re-teaching often resulted in further crashes as the production line is extremely restricted in terms of space and welding points in the wheel arch, for example, can only be modified to a limited extent without incurring the risk of another collision.
What made things more difficult was that the re-teach work had to be carried out for all models. These were not available, however, at the time the work was being carried out. It could be that the model would not appear until the next shift. If the operator forgot to stop the line and adjust the robot programs, another crash occurred.
The task also included ensuring that the Comau robot could be replaced. For this type of robot there is no repeatable and verifiable procedure for mastering.