May 2026 Volume 8

AUTOMATION

FIA members share practical advice for forging companies taking their first steps, from testing systems in real production to preparing the entire organization for change. STARTING SMART WITH AUTOMATION By Angela Gibian

That kind of trial can require extra planning. It may mean shifting production schedules, coordinating engineering support or making room in an already busy operation to test equipment under real conditions. But Wilson argues that the effort pays off because it gives companies the chance to validate and fine-tune an engineered solution before moving to full implementation. That is an important distinction. On paper, many automation systems can look ready-made for a process. In practice, however, the realities of a forging environment often expose issues that only show up on the floor. A trial can reveal whether access is adequate, whether cycle timing works, whether the tooling accommodates the equipment and whether the automation integrates smoothly into the wider operation. For first-time adopters, that kind of real-world testing is not just helpful — it is strategic. It gives companies a chance to learn before they fully commit capital, time and labor. It also helps build confidence internally, especially among the people who will ultimately work with and support the system every day. Just as important, a trial helps companies move past a common misconception: that automation can be installed once and left alone. Wilson cautions that automation solutions are not perfect and do require preventive maintenance. Even when integrators and equipment providers design systems to be as simple and reliable as possible, they still need routine attention to perform at their best. That reminder matters because companies new to automation often focus heavily on the front end of the investment — selecting equipment, justifying cost, planning installation — without fully accounting for what happens after startup. But long-term success depends as much on maintenance readiness as it does on the initial purchase. In a forging environment, that is especially true. Heat, lubricants, scale, vibration and wear all place demands on equipment. Automated systems operating in those conditions need cleaning, inspection and preventive service to maintain performance. Without that support, consistency can slip, downtime can grow and frustration can replace the early promise of the investment. The takeaway for companies at the beginning of their automation journey is simple: Maintenance planning belongs in the early stages, not later. Who will be responsible for upkeep? What training will be needed? What preventive maintenance schedule will be followed? What spare parts should be on hand? Those are not side questions. They are part of the foundation. “Automation solutions are not perfect and do require preventative maintenance.” — Mackay Wilson, P.Eng., AED Automation

F or forging companies considering automation for the first time, the opportunity is real — but so is the learning curve. Across the industry, companies are exploring automation to improve consistency, support safety, address workforce challenges and strengthen long-term competitiveness. But for shops just beginning that journey, the first questions are often the hardest: Where do we start? What should we expect? And how do we avoid investing in a solution that creates new problems instead of solving old ones? Advice from FIA members points to a clear answer: Start with realism. Successful automation is rarely about installing a machine and watching results appear overnight. More often, it comes from testing carefully, planning for upkeep, involving multiple departments and giving the process time to mature. For forging operations, where conditions are demanding and processes are deeply interconnected, those fundamentals matter. Mackay Wilson, P.Eng., area sales manager at AED Automation, has seen the value of that approach firsthand, particularly in the automation of lubricant spray. His first piece of advice to companies is straightforward: trial before commitment.

“Full implementation of an automated solution will be that much more successful if a real-world trial with automation equipment can be completed.” — Mackay Wilson, P.Eng., AED Automation

FIA MAGAZINE | MAY 2026 38