May 2026 Volume 8

SAFETY

Automation as a Safety Tool Automation in forging is often discussed in terms of productivity or consistency, but many of the most immediate benefits appear in the safety domain. Several areas of forging operations lend themselves particularly well to automation from a risk-reduction perspective. Automated billet handling Handling hot billets manually introduces obvious risks related to burns, dropping material, or repetitive strain injuries. Robotic loading systems and forging manipulators can transfer heated billets from furnaces to presses without requiring operators to work near extreme temperatures. Automated press feeding Loading and unloading forged parts from press dies is one of the most common points of human interaction in forging processes. Automated feeding systems remove the need for operators to place their hands near die areas, dramatically reducing pinch and crush hazards. Robotic trimming and secondary operations Automated trimming cells allow forged parts to be positioned and processed without manual intervention. This reduces exposure to sharp edges, part ejection, and repetitive manual handling. Integrated material transfer Conveyors, robots, and automated transfer systems can move parts between forging, trimming, and inspection stations in a predictable, controlled manner. This reduces reliance on forklifts and manual carrying of heavy components. In many cases, these automation solutions also introduce additional safety layers through sensors, machine vision, and process monitoring systems that detect abnormal conditions before they escalate into dangerous situations. “A lot of the risk in forging comes from asking people to do the same high-exposure tasks over and over,” says Jeffrey Walsh, Director of Business Development at Macrodyne. “When you automate those steps, you’re not replacing people. You’re taking them out of the most dangerous parts of the job.” The Misconception That Automation is Only for New Factories Despite these advantages, some forging manufacturers remain hesitant to adopt automation, particularly in facilities built decades ago. A common perception is that automation requires a completely new production line or a fully modern factory environment. In reality, many automation systems can be integrated into existing operations through retrofits and modular upgrades. “Most forging plants weren’t built yesterday,” says Kevin Fernandes, President of Macrodyne. “The reality is, you don’t need to start over to improve safety. In many cases, you can integrate automation around existing equipment and take meaningful risk out of the process.” Older presses can often be paired with robotic feeding systems. Billet loading systems can be added without replacing furnace equipment. Transfer automation can be installed between existing stations to reduce manual handling. Rather than requiring a complete transformation, automation can

often be introduced incrementally, targeting the highest-risk or most repetitive tasks first. This approach allows manufacturers to improve safety while maintaining continuity of production. Addressing Workforce Concerns Concerns about job loss are not theoretical. They’re real, and they come up in nearly every conversation about automation. In forging environments, where skill, experience and hands-on knowledge matter, those concerns carry even more weight. Operators are not just labor. They are an integral part of how the process works. But in practice, automation rarely removes that expertise. It just changes where and how it is applied. Operators who previously performed repetitive or hazardous manual tasks often move into roles that involve monitoring automated systems, overseeing production flow, or managing quality inspection. These roles typically require a higher level of technical understanding, but they also involve significantly lower physical risk. That transition does not happen automatically. It requires deliberate investment in upskilling and support. Companies that see the most success with automation aren’t just installing new equipment and calling it a day; they are committed to developing their workforce alongside it. Because in many cases, the challenge isn’t replacing people. It’s finding them. In U.S. forging, where machine operators face a projected 19% employment drop amid chronic shortages 8 , automation sustains production by eliminating manual tasks like billet loading that are increasingly hard to staff. Rather than replacing the workforce, automation often allows experienced operators to apply their expertise in safer and more sustainable roles. The Economic Dimension of Safety Safety improvements are often framed as compliance obligations. But in practice, they carry direct and measurable economic consequences. Workplace injuries introduce immediate costs: lost production time, equipment downtime, regulatory penalties, and workers’ compensation expenses. In high-output environments like forging, where processes are tightly coupled and downtime cascades quickly, even a single incident can disrupt far more than one station. Across U.S. manufacturing, injury-related costs exceed $58 billion annually. That’s more than $1 billion per week driven by machine incidents, material handling injuries, and unplanned interruptions. 9 But the direct costs are only part of the picture. Insurance premiums and liability exposure can rise following serious incidents, particularly in operations with repeated or high severity claims. At the same time, indirect costs often extend much further than expected. Production interruptions, retraining replacement workers, missed delivery timelines, and reputational impact can continue to affect operations long after the initial event.

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