February 2021 Volume 3

AUTOMATION

FIA Members Talk Automation

Walker Forge is a 70-year-old, diversified producer of closed, impression die forgings. The manufacturing operations are located in Clintonville, Wisconsin and, like many a manufacturer today, there are vivid memories of our now historical ‘day of transition’. In this case, I am referring to the day our forging operation moved to install and make robotics a plant reality. The reasons for my decided focus on the ‘day of transition’ are many and varied. I firmly believe that how you get to ‘the day’ is quite important relative to where you are with robotics today or in the future. I am guessing that almost everybody that reached the day of transition went through some kind of a justification to move forward with robotic automation. I am sure it included some combination of the following: A labor cost reduction with improved productivity and process control, possibly with some ergonomic benefit sprinkled on the side. How this justification and planning process all worked out, especially here at Walker Forge, is probably the reason we now have many robots, versus none or few. Recalling that ‘day of transition’, some 20+ years ago…April 1, 2000, the justification process took quite a bit of time. The data collection, analysis, planning and communication started a full eight months in advance of that day (decision day to transition day), with an overriding understanding, from previous experience, that you have one shot at making this work. Buy-in and collaboration are frequently discussed human resource action strategies, albeit sometimes very difficult to attain. The extra work necessary to support the human in this case was essential to our success. We did NOT create this project in a vacuum. Everyone participated, and still not everyone was optimistic. Dealing with all the human perspectives is necessary because, essentially, it won’t work if someone wants it to fail. The best part of “it’ll never work” is, obviously, when it works.

Robot #1 was a success in that it caused few issues and did what we wanted it to do, and, maybe more significantly, what we said it was going to do. Robot #2 quickly followed in an almost identical application. Robot #3 was a special application. The decisions that allowed others were only possible because of the results of #1, #2 and #3. We have since created and expanded our own Automated Manufacturing Department, making it one of the structural supports of our raison d’être. The continued success of any technology-based process needs to include a path that provides for advanced training and experimentation. Needless to say, we are focused on both. ■ Rick Recktenwald President Walker Forge Phone: 414-223-2754 Email: Richard.Recktenwald@walkerforge.com

FIA MAGAZINE | FEBRUARY 2021 27

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