November 2023 Volume 5

AUTOMATION

FIA Automation Adoption Initiative: Rapid Training of ‘Robot Heroes’ By Jim Warren and Jim Morris

Specific Applications of Automation for Forging Projects that have the quickest payback will be targeted. 1. “Heater” Automation Robotic unloading of hot billets from a furnace/induction heater and place into the forge press at station 1. ROI = 30% + due to labor savings (1 man per shift), higher quality, faster throughput. 2. Press Tending Robotic part handling to advance parts from station to station while interfacing with die spray equipment and the press. Possibly place forged part onto a cooling conveyor. ROI = 30%+ due to labor reduction (1 man per shift), less die wear due to more accurate part placement, faster throughput, higher quality. 3. Trim Press Tending Robotic part handling to pick the “as forged” part and load into a trim die, remove the flash and or part if appropriate, place part onto a cooling conveyor or into a bin. Payback = 30%+ due to labor reduction(1 man per shift), higher quality due to more accurate part placement, less die maintenance. 4. Grinding Automation Robotic removal of flash with a grinding wheel or belt. Payback = 25%+ due to labor reduction, higher quality, fewer consumables, fewer injuries. Next Steps FIA continues to track our lobbying efforts to secure an appropriations award from the U.S. Congress. In addition to this, we have applied for grants from various DOD units; have stayed active meeting with our DOD contacts, and recently attended the Association of the United States Army (AUSA) show in Washington D.C. to make new contacts with the military branches, OEMS and Primes. For more information on FIA’s efforts to secure government funding for our industry, contact Jim Warren, FIA President & CEO, at jwarren@forging.org.

The North American forging industry has the need and desire to automate its production equipment. Over the last six years FIA’s leadership has emphasized through conferences, plant tours and published articles the benefits and knowledge of forging automation – for captive forgers and job shops alike. At present, much of the global forging capacity (over 40% in China alone) is centered in Asian based countries. The North American forging industry needs to exist and be robust with capacity and commercially viable if we are to answer the call to provide forgings for our defense. Hence, the FIA Forging Automation Initiative was launched in December of 2022 at the Defense Manufacturing Conference in Tampa, FL. The FIA Automation Adoption Initiative vision is to use mobile training platforms to rapidly accelerate the implementation of automation in the forging industry. Using robots to perform material handling of hot parts through the forge and trim press has been demonstrated to expand production capacity by up to 30%, reduce costs, improve quality, and reduce injuries. Robotic technology is being used to produce vital components for the nation’s armed services such as munitions, tracked vehicles, small arms, heavy trucks, air frames, and aircraft engine components. Many forging producers want to implement robotics into their processes, but do not have a ready pool of robotic operators and programmers. Traditionally, this skill set is acquired by attending vocational and two-year technical schools. However, due to demand, it is necessary to go faster and create more skilled robot operators, or as we like to say, “robot heroes.” FIA has been working toward securing government funding aimed at increasing the level of technical expertise at the plant level by taking the “school to the factory.” If successful, the funds will be utilized for a pilot program that will take mobile training platforms (RoboCarts) to the factory. While not a new concept, the FIA RoboCart will include both forging and casting features on the carts. Specifically for the forging cart, build outs will include 1) a pick-n-place example – robot picking-n-placing a billet and 2) a grinding example. Along with the RoboCart, FIA will commission an 80-hour curriculum including 32 hours of basic robot operation and programming instruction, 32 hours of advanced programming and troubleshooting, and 16 hours of special instruction directly related to press tending and grinding application techniques. Completion of the course will give trainees a solid understanding of robot operation, troubleshooting, and programming, eliminating a major impediment to adoption in the forging industry. Testing will be incorporated in the training, leading to an industry recognized certificate backed by FIA.

Jim Warren President & CEO Forging Industry Association Phone: 216-781-6260 Email: jwarren@forging.org

Jim Morris Exec VP Business Development Automation for Manufacturing Phone: 607-481-4465 Email: jmorris@auto4mfg.com

FIA MAGAZINE | NOVEMBER 2023 18