How to improve the level of automation in the metal stamping industry

How to improve the level of automation in the metal stamping industry

The emergence of Covid-19 has revealed the importance of automation: With the reduction of human resources in metal stamping workshops, metal forming operations that automate waste streams and utilize the Industrial Internet of Things will be more efficient and therefore more resilient. Additionally, workplace safety is improved as automation supports the physical evacuation of employees and reduces overall contact with equipment and tools.

How to improve the level of automation in the metal stamping industry

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  As the manufacturing industry recovers from the impact of COVID-19, one thing has become clear: Skilled worker shortages will continue to escalate, and the stamping industry needs to prepare and adapt to this challenge.

  A new survey by a large manufacturing technology company reports that 21% of respondents said the emergence of COVID-19 has revealed the importance of automation. Metal forming operations that automate scrap flow and leverage the Industrial Internet of Things (IIoT) will be more efficient and therefore more resilient as shop floor human resources are reduced. Additionally, workplace safety is improved as automation supports the physical evacuation of employees and reduces overall contact with equipment and tools.

  Five areas where increased automation in stamping and die making processes can not only help alleviate existing skilled worker shortages, but also facilitate future growth for stamping manufacturers are scrap, fluid management and monitoring.

 1. Mobile scrap metal

 Conveyors, hydraulic dumpers and automatic feeding systems eliminate some of the most laborious manual processes in metal scrap handling.

 Conveyors: Conveyors quickly and automatically remove stamping waste and debris from the start of production. When scrap metal and spent cutting fluid are automatically removed from core operations, forklift transfer is no longer required and production cycles are optimized.

 Auto dumper. They receive chip carts or drums from die machining operations, then lift and flip them onto receiving hoppers. Mechanical options are equipped with advanced transfer capabilities; hydraulics facilitate low-level metal scrap transfer. Both systems are efficient for single-person trolley unloading if hand-held controls are used to guide the operation.

 Loading Systems: These systems automatically transfer scrap metal into distribution containers for transport to metal recycling stations. The continuous back and forth operation of the reciprocating conveyor distributes the waste material evenly in the container. When the container is full, the level sensor alerts the operator. Loading and unloading automation can even use machine-to-machine communication to signal scrap dealers that containers are ready for pickup. Overall scales can track overall scrap production and help ensure containers are full, but also within road weight limits. These systems greatly reduce the supervision required for efficient loading.

 Automatic transfer of scrap metal from one production site to another minimizes employee intervention. And, because these systems eliminate the hazards associated with manually moving scrap metal, workplace safety is improved. This can help attract and retain high-quality employees, while allocating resources for production-focused tasks in other areas of operations.

 How to improve the level of automation in the metal stamping processing industry

 2. Modify metal scrap

 Metal scrap handling equipment automates the task of reducing the turning and clumps of metal chips into flowable shovel chips. Equipment with vertical feed provides continuous positive feed operation to reduce bulk waste. Equipment with horizontal feed can accommodate a small number of narrow turns.

 These systems help keep workshops free of hazardous materials and prepare scrap metal for more efficient line processing.

 3. Monitor the machine

 As experienced older workers leave, automated machine monitoring and IIoT capabilities provide a path to success for stampers who lack adequate knowledge of facility equipment and maintenance resources. Automated machine monitoring systems continuously monitor equipment performance and capture data to support predictive maintenance. Ultimately, downtime can be minimized, maintenance costs can be reduced by reducing labor overhead, productivity can be increased, and workplace safety can be improved throughout the operation.

 Because IIoT communication devices collect device data and send it to the cloud, they make device data accessible to any person or device, anywhere. This can help new operators see what has caused machine failures in the past and make machine uptime more predictable. The IIoT can even send emails to suppliers to automatically order replacement parts.

 4. Separation of cutting fluid

 Operation after die cutting, wringer and centrifuge can separate cutting fluid from metal chips. Especially when they are inserted into metal chip handling systems, wringers and centrifuges help to automatically remove and recycle cutting fluids, helping to speed up waste stream management. An automatic lubrication system for wringers and centrifuges with self-cleaning design and self-lubricating bearings helps support continuous operation while reducing operator-led procedures.

 5. Manage cutting fluid

 For stores lacking automatic fluid filtration systems, cutting fluid management requires repeated employee intervention. Operation with a flow oil separator eliminates the need to manually clean the oil in the flush tank. Flow oil separators reduce flow oil to less than 1% at a time by automatically removing free-floating and mechanically dispersed flow oil, bacteria, mucus and inverted emulsions from individual machine oil sumps, central systems and wash tanks

 Turnkey centralized fluid filtration system further improves fluid management efficiency by automatically controlling coolant concentration and continuously eliminating bacteria through ozone injection. These centralized systems require minimal operator involvement and training, making fluid management easy, seamless and easy. Cutting fluid recycling equipment can also reduce hazardous waste disposal by up to 90 percent and reduce new fluid purchases by up to 75 percent.

 While automation offers a path to future resiliency, it is still plagued by the stigma of the past. To take full advantage of the level of innovation that automation offers, North American manufacturing, including metal forming operations, must first dispel the misconception that automation can only eliminate jobs, when it turns out that automation can help create new jobs. An automation study by Deloitte in the UK showed that while 800,000 low-skilled jobs were eliminated, 3.5 million high-paying jobs were created.

 Companies that deploy automation technology in their operations tend to grow, and those that don't wither tend to grow. As such, automating waste streams is a way for North American stamping companies and their employees to make progress, and a way to increase operational resiliency that will allow plants to grow even in the most challenging economic conditions.