May 2023 Volume 5

AUTOMATION

to smallest diameter parts, shortest to longest lengths. A good integrator will test the ‘corners of the box’, even create mock-ups at their site. If possible, the forger should send the dies along with the part attribute information.” Trizzino of Adaptec Solutions adds, “Current material flows from raw materials to finished product should be defined and shared, as well as the current technology that the new system is expected to interact with. This information will greatly help in early discussions with potential system integrators.” Clearly, taking the time to prepare, research and decide on a system integrator is a very important step.

temperature range. A forger should be aware of them. In addition, a robot should not be subjected to wet conditions (rain, snow). This includes providing clean, dry compressed air.” While this may sound obvious, he shared several stories that shocked me. Jim continued, “Understanding your current power condition is important. Automation is tolerant to fluctuations, but to a point. Power condition must be decent.” The work environment in a forge can be challenging. “The robot shouldn’t be subjected to excessive vibration. This isn’t usually an issue as the forge is on its own foundation. However, the foundation on which the robot will sit sometimes is a problem. It needs to be level, and free of cracks.” Something both Mario and Jim brought up involves existing equipment and the technology it uses or doesn’t use. Trizzino says, “A real hidden cost can be the upgrades necessary on existing equipment so that it can communicate with the automation.” This includes, the forge, trimmer, induction heater, and the like. Morris adds, “Relatively modern PLCs need to be installed on the forge, as well as secondary equipment. A cell controller can be included in the system design to act as a ‘traffic cop’ to ensure everything is working together. If the equipment is very old, and still using mechanical cams, forget it, you can’t communicate with it.” Much to consider for sure. Assessing current work conditions and identifying potential problems ahead of time will greatly help the forger make better decisions and develop better plans. So, how are your current work conditions? Summary Automation can certainly provide important benefits to a forging company. But before making that big investment, it is important to go into the process clear-eyed and with the knowledge necessary to make informed decisions. A forger should consider the suggestions presented before taking the plunge. By doing so, you can avoid some common pitfalls experienced by those who went before: pitfalls that can have substantial economic cost or at least delay the return on a very significant investment.

Looking Inwards I asked both Jim Morris and Mario Trizzino about the internal capabilities necessary before investing in automation. First, Jim. “I always ask business leaders considering automation who will be the ‘robot hero’, who is going to keep it working?”. Mario refers to this person as a ‘champion’ or ‘owner’. “A system integrator can train personnel in system specific programming, how to add a new part number, troubleshooting. But they can’t teach discipline. A strong champion must have the right attitude and mindset and be willing to teach others”, Mario explained. Jim adds, “It’s not so much programming but rather troubleshooting skill that is important. The person doesn’t have to be an expert programmer, but needs to be able to read the program, understand how it works, and respond to error messages.” So, who will be your ‘robot hero’? How about internal maintenance skills? Both gentlemen agreed that no real special skills are required. Most preventive maintenance involves lubrication, and simple programs to ‘exercise’ the robot as part of grease changes can be written. While training is available, it might be easier to set up an external resource to perform the necessary typically annual preventive maintenance. The robot OEM, and some not all system integrators provide such services. Another thing to consider when identifying potential system integrators. Given my personal experience over the years, I asked about existing work environment considerations. I have found that this is often an afterthought. Jim Morris had much to contribute on this topic. “Robots operate within a maximum and minimum

Drew Locher is managing director of Change Management Associates and can be reached at drewlocher@comcast.net

FIA MAGAZINE | MAY 2023 35