November 2022 Volume 4

AUTOMATION

blueprint in mind, the lack of labor has to be addressed. How does robotic automation alleviate that? Adaptec’s Jim Morris takes on this subject, noting the effect automation can have on attracting younger workers. He says, “One thing we’ve observed in other industries is you put robots in a plant, and you know, they’re high tech and exciting for the younger folks. We’ve seen the effect of that automation attracting younger workers because you can walk out on the floor and say, ‘you’re going to get to work with this type of equipment.’” For those who aren’t able to witness automation at work, visiting plants with robots in action can inspire younger generations to want to be a part of the industry. “Adding a robot, you don’t lay people off – you move them over into a job where they use their brain more than their hands. Robots are force multipliers.” Morris brings to light the inconsistency in education when it comes to manufacturing, specifically in high schools and community colleges. He states, “Unfortunately, they’ve had a roller coaster ride in terms of what they’re going to train people on,” as programs focus on trending subjects rather than general manufacturing education. For example, schools local to Morris developed programs for fiber optics until the trend faded and students were pushed into other areas that needed staffing. He makes a solid point – that nationally, students just need to understand basic manufacturing and forging will naturally be a part of that. The roadmap to success starts at the high-school level, then up to community colleges, and eventually to four-year universities. Morris’ point of “trying to put that roadmap back together to attract younger people in the industry” is followed up by Warren’s statement that high-tech environments with impressive technology make it easier for some companies to hire. M.K. Morse, a saw manufacturing company, is an example of this. During a tour of their facility, Warren brought up the labor shortage to find that in a company with about 500 people, they only have seven job openings. The high-tech environment, full of impressive technology, Warren thinks has a lot to do with their hiring success. As they look to eliminate the hands-on, intensive process in their powder coating line, Warren asks an important question – where those people are going? The answer: “Oh, we have places for all the people.” Following up Warren’s point, Morris argues against the stigma that adding robots lays people off stating, “Adding a robot anymore, you don’t lay people off – you move them over into a job where they use their brain more than their hands. Robots are force multipliers.” Hunsinger then brings the conversation back to education and the importance of getting those curriculums back into high school, community colleges, and even 6–12-month technical degree programs. By doing so, students are able to explore avenues that they did not know were there. Training &Workforce Development Morris highlights training opportunities that are available to companies who integrate robots into their processes. Adaptec’s unique training program allows instructors to travel to the end

user to facilitate classes with training robots, unlike other programs that require travel to the training site. Operators are able to become familiar with the technology without having to be off site for a long period of time. Warren adds to conversation by looping in military investments in workforce development, exemplifying the need to replicate Adaptec’s training method in schools to expose students to the manufacturing industry. Continuing the defense conversation, Warren applauds the United States’ ability to equip Ukraine with weaponry. The key fact here is that forgers have been keeping busy in that space despite the consensus that we are not built as were in the 50s during WWII. Warren says, “The U.S. just is not that industrial might anymore and our top leaders are concerned.”This is an important time for forging to step up as we’re a little behind on the world stage of automation. With the help of integrators like Adaptec, and companies such as Bonney Forge, everyone is doing their part to push the forging industry forward. Forging University Forging University, an online, web-based training center with interactive courses presented by the FIA, makes it easy for people to see the first steps of automation in case they can’t attend workshops. Morris reflects on his experience at the very first show in Chicago, and how four years later, he’s back again with a much bigger crowd. During his workshops, Morris asks his attendees if they are using robots currently. The first time, not too many hands went up. This time, about 40% of those attending raised their hands. He adds, “Robots and automation are definitely starting to become entrenched in the industry.” Even the people that haven’t started using automation are going to be soon. As Morris says, “This stuff just works.” Robotic Integration Trizzino shares his insight on robotic integrators, specifically the knowledge and expertise it takes to break into the forging industry. Due to the uniqueness of processes, some integrators haven’t had the ability to break into the sphere of forging yet. Many forging processes are intimidating by nature as they usually include dangerously hot parts. Trizzino taps into his engineering background and says, “As an engineer, how do you design something that isn’t going to burn up?” He reflects on his career as a young engineer right out of school, working under Morris to learn the industry. He was able to do some forging design, learning from someone who had the experience and knowledge to coach him through it. Working for integrators such as Adaptec and LASCO, for example, the younger generation has a chance to learn tips and tricks from those familiar with the industry. Once an integrator understands the industry, they can learn customer’s processes to figure out how to automate handling hot parts. Trizzino continues with a great point – although the forging industry is unafraid of forging’s dangerous

FIA MAGAZINE | NOVEMBER 2022 35