August 2026 Volume 8

EQUIPMENT & TECHNOLOGY

8. What training and support do you provide during and after installation? Even the best equipment will underperform if operators, maintenance teams, and supervisors are not properly trained. Training should be part of the project plan, not an afterthought. Forgers should ask whether the supplier provides onsite training, documentation, troubleshooting guides, maintenance instruction, operator training, and refresher support. It is also worth asking whether training is customized to the specific equipment and application. Training should not stop at startup. As Robert Brodhead of DAUCH emphasized, troubleshooting and training during and after startup are critical. Forging operations need to know who is trained, what documentation is available, how quickly support can be accessed, and whether the supplier can assist when production conditions change. Ask: What training is included, who should participate from our team, and what support is available after startup? Automation Leads the Way in Equipment Upgrades A recent Forging Industry Association LinkedIn poll asked forging professionals which equipment upgrades have made the biggest difference in their operations. While the informal survey received a limited number of responses, the results point to a clear theme: Forgers are prioritizing automation and technologies that improve productivity, consistency and efficiency. Automated billet loaders, quick die-change systems and hammer or press automation each received 33% of the vote. Real-time temperature monitoring received no votes in this particular poll, although temperature control remains an important consideration for maintaining process consistency and product quality. The three-way tie suggests there is no single upgrade that delivers the greatest value across every forging operation. Instead, the most effective investment often depends on a plant’s processes, equipment, production volume and workforce needs. Automated billet loaders can reduce manual material handling, improve cycle times and help limit employee exposure to hot material. Quick die-change systems can minimize downtime between production runs, improve equipment utilization and support facilities managing a diverse mix of parts. Hammer and press automation can improve process repeatability while reducing physically demanding tasks and dependence on manual intervention. One respondent highlighted another area where automation has produced meaningful results. They stated that “Replacing manual lubrication application with robotic lubricators featuring air impression cleaning” made a significant difference. Automated lubrication systems can help deliver more consistent lubricant coverage, reduce unnecessary material use and remove scale or debris from the die impression between cycles. The responses reinforce a broader industry trend: The most valuable upgrades are often those that remove repetitive manual tasks, reduce downtime and give operators greater control over the forging process. For many plants, targeted automation may provide a practical path toward improved safety, quality and throughput without requiring a complete equipment replacement.

recommended inspection intervals, common wear points, and expected component life. They should also ask whether the equipment is designed for ease of maintenance, especially in high production environments. Maintenance planning should include both routine preventive maintenance and practical troubleshooting. Robert Brodhead of DAUCH noted that he typically asks about troubleshooting and training during and after startup. That is an important point: a supplier’s value is often tested when something does not go according to plan. Ask: What preventive maintenance schedule do you recommend, which components typically require the most attention, and what troubleshooting support is available after startup? 6. What spare parts should we keep on hand? Unplanned downtime can be costly. For many forging operations, waiting days or weeks for a critical replacement part is not an option. Before purchasing equipment, forgers should ask suppliers to identify critical spare parts, recommended inventory levels, lead

times, and whether parts are stocked domestically or must be imported. This conversation is especially important for older equipment, custom systems, imported machinery, and equipment that supports mission-critical production. Suppliers should be able to provide a recommended spare parts list tied to the equipment’s expected operating conditions. Forgers should also ask which parts are proprietary, which can be sourced from multiple suppliers, and which components have long lead times. Ask: Which parts are most critical to keep in inventory, and what are your standard lead times? 7. How will this equipment integrate with our existing operation? New equipment rarely operates in isolation. It must work with current presses, hammers, furnaces, tooling, manipulators, robots, transfer systems, controls, safety systems, and plant layouts. Forgers should ask suppliers to review the full production environment before finalizing a recommendation. This includes space constraints, foundation requirements, power needs, material flow, operator access, maintenance access, and upstream and downstream process requirements. Integration should also include the human side of the operation. Will operators need to change how they load, move, inspect, or process parts? Will maintenance teams need new tools or procedures? Will supervisors need new data or scheduling information? The best equipment recommendations account for the entire process, not just the machine. Ask: What information do you need about our current process to ensure this equipment integrates successfully?

18 FIA MAGAZINE | AUGUST 2026