The ultimate aim of this project is to develop a self adaptive rapid algorithm based on the captured image of the work piece. the image of the work piece was captured from the ni guppy pro f031c camera which has 300 dpi with 120 fps resolution. the captured image was transferred to the virtual instrumentation (labview) for developing the self adaptive algorithm through rs232 serial communication protocol. the labview vision assistant module was used to develop an algorithm based on the geometry of the captured image. the various image processing operations like thresholding, morphological operation (thinning), and edge detection. the caliper tool was used to measure the distance between the coordinate points (welding distance). with the aid of visual basic, the measured values were converted into coordinates. the coordinates were used to develop a rapid program with the aid of abb robot studio library functions. the virtual server was established between the abb robot studio and irc5 controller with the use of mod-bus protocol with visa. after receiving the data from the mod-bus, the irc5 controller moves the abb industrial robot end effector along with the welding gun for the welding purpose. the work piece was located on the designed jigs and fixtures. the different types of welding with different design can be incorporated with the vision assistant module for further development. this will be very useful for the industrial environment.