May 2026 Volume 8

AUTOMATION

RETHINKING AUTOMATION IN A JOB SHOP How AI and Smart Systems Are Changing Forge Tooling By Bailey Taylor

W hen the topic of automation and material handling comes up in the forging industry, the conversation typically centers around large-scale production environments. Robotics, conveyors, automated part transfer systems, and fully integrated press lines dominate the discussion, and for good reason. These technologies are critical to improving throughput, consistency, and safety in high-volume forging operations. But for smaller, job shop-style suppliers, like EST Tool & Machine, Inc., particularly those focused on forge tooling, the definition of automation looks a bit different. At EST Tool, we don’t operate forging presses or automated transfer lines. Our role is to support the forgers who do. As a result, our approach to automation isn’t centered on moving hot steel from point A to point B. It’s focused on something less visible, but equally impactful: streamlining the flow of information. In today’s environment, where lead times are tight, margins are scrutinized, and expectations for responsiveness are higher than ever, the ability to move data efficiently through a shop can be just as valuable as moving material. Automation Beyond the Shop Floor For many job shops like us, especially those operating in high-mix, low-volume environments, traditional automation can be difficult to justify. The variability between jobs, frequent changeovers, and custom nature of the work limit the effectiveness of rigid automation systems. However, that doesn’t mean automation isn’t achievable. It simply shifts where the focus lies. Instead of automating physical processes, we’ve focused on automating digital workflows. This includes everything from quoting and job setup to programming documentation and tooling management. These are areas where small inefficiencies can compound quickly, especially when dealing with complex tooling packages and multiple customer requirements. By addressing these internal processes, we’ve been able to create a form of “soft automation” that reduces manual input, improves consistency, and frees up time for higher-value work. The Role of AI in a Modern Tooling Shop One of the most significant enablers of this shift has been the rapid advancement of AI-driven tools, particularly large language models (LLMs). While AI is often associated with futuristic applications, its practical use in a manufacturing environment can be surprisingly straightforward.

At EST Tool, we’ve begun integrating AI-assisted coding tools into our daily workflows. These tools allow us to rapidly develop custom scripts and lightweight applications tailored to our specific needs, without requiring a dedicated software development team. For example, we’ve developed systems that automatically generate programming sheets by pulling data from multiple sources. Information from our ERP/CRM, tooling inventory, and job specifications is consolidated into a single, structured document. Tool lists are dynamically linked to our inventory, pricing is tracked in real time, and key job data is automatically populated. What was once a manual, multi-step process is now largely automated. This not only saves time but also reduces the risk of errors, something that is especially important when dealing with high value tooling and tight delivery schedules. Connecting Disconnected Systems A common challenge in many shops is the lack of integration between systems. ERP platforms, inventory databases, quoting tools, and documentation often exist in silos. As a result, employees are forced to manually transfer information between systems, increasing the likelihood of inconsistencies. By leveraging custom code and AI-assisted development, we’ve been able to bridge some of these gaps. Rather than replacing our existing systems, we’ve focused on connecting them. Simple scripts can pull data from one platform, format it, and push it into another. Over time, these small connections add up, creating a more cohesive and efficient workflow. This approach is particularly valuable in a job shop environment, where flexibility is key. Instead of investing in large, rigid software implementations, we can build and adapt tools as our needs evolve. Automating the Small Things One of the biggest misconceptions about automation is that it has to be large-scale to be worthwhile. In reality, some of the most impactful improvements come from automating small, repetitive tasks. In our case, this includes: • Auto-populating job travelers and setup documentation • Linking tooling lists directly to inventory and cost data • Tracking tooling spend at the job level in real time

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