May 2025 Volume 7

AUTOMATION

PC is a process control center connected to your plant’s ERP system, and the data collected is used to optimize your productivity, product quality, and the life of the machines in your forging cell. The PC is different than the PLC, which is the master control of the forging process located at the cell. The remote PC collects all the data from the PLC, then stores and interprets the data for the operator to effectively monitor production and maintain the forging cell. The operator is also needed to run the PLC and safely activate the forging cell. Once the forging cell is activated, the operator returns to the remote PC to monitor the forging production. Improved Productivity, Quality, and Efficiency Sensors installed into the integrated automated forging cell assist the operator to effectively monitor the forging process. This is particularly essential in the hot forging process. Using a printer connected to the PC, the operator prints and applies a label on each bin of good parts, scraped parts, rejected parts, or billets that are just a little low in temperature. Integrated automation helps you reduce waste, because you can reuse those billets. If the forging cell stops for any number of reasons, the billets exiting the induction heater will be automatically counted and directed into a bin for future reuse. If there is a failure of the induction heater, and the billets are overheated, these pieces are counted and ejected into a scrap bin. The system will generate bin labels showing how many billets are in each bin and which billets are rejected, reusable, or good forged parts. Say that you put 1,000 billets in the induction heater. At the end of production labels are automatically printed with the outcome – 900 good pieces, 50 billets can be reused, 50 billets scrapped. Working with integrated automation, your operator can increase productivity, quality, and efficiency. Protecting Your Investment The application of sensors is vital to controlling the correct functionality of each press. Our Siemens software is able to monitor critical information enabling predictions of possible failure. For example, our FICEP cutting shears have temperature sensors in the main bearings detecting heat that would cause premature wearing of bearings, bushings, and other components. This provides the operator with early warning so preventative maintenance actions can be scheduled to protect your investment. FICEP’s Teleservice is also available, allowing engineers to track sensor generated data and provide preventative and predictive maintenance service remotely. The Importance of Preventative Maintenance Automated forging cells maintain the highest standards of preventative maintenance. Programming consistent routine maintenance makes your forging cell reliable. Industry 4.0 is the standard for forging producers to operate their machines efficiently at their optimal condition. You do not want to stop your forging cell while you are in production. This is reactive maintenance,

not proactive maintenance. You will have a lower cost and shorter downtime when you schedule maintenance instead of forging with a worn or damaged machine or stopping production in the middle of a job. Many forging producers that I talk to say that they often wait to service their machines in order to save money. I say, be careful. Because if you wait until it is fully broken the cost to repair it is higher. You may not want to stop the machine while you are in full production because you have a big job, however, if you delay too long you could lose the job, the customer, and the machine. Going Automated: If Not Now – When? About 75% of our customers are purchasing fully automated forging cells. Even beyond forging, this is where the manufacturing industry is going. The decision to automate is a matter of investing in the future of your company and the future of the forging industry. It is important to understand that integrated automation is not a matter of adding a robot to perform a single step in the production process. It is a series of mechanisms engineered to take the entire forging process to the highest level of productivity. When looking at a new forging cell delaying the decision to automate can add an additional layer of integration complexity and cost not to mention leaving enough room in the shop for the complete cell. For this reason, automation plans are best made in advance.

Peter Campbell Campbell Press Repair U.S. Sales & Service FICEP Phone: 517-388-1403 Email: pc@campbellpress.com

Carlo Maffei Commercial Director Forging Division FICEP S.p.A. Email: carlo.maffei@ficep.it

FIA MAGAZINE | MAY 2025 35