Automation of manufacturing processes in the metalworking industry

The vast majority of sheet metal manufacturers seek best practices to optimise productivity and increase efficiency in order to remain competitive. In recent years, the automation of manufacturing processes in the metalworking industry has evolved significantly, and a growing number of solutions can provide significant value to businesses.

The following explains the most important ways in which the automation of manufacturing processes in the metalworking industry benefits manufacturing and how workshops can use it to their advantage.

Advantages of automation of manufacturing processes in the metalworking industry

1. Improving worker safety

   Automated solutions can help reduce the number of tasks that workers must perform, which translates into a much safer workplace.

   The reality is that people face several threats in a metal fabrication workshop. Critical tasks such as welding and cutting are inherently dangerous, and the heavy equipment needed to move and package raw materials can also pose safety risks. Risky, tedious, and repetitive tasks are often prime candidates for automation, which will help keep workers safe.

   Manufacturing plant personnel face significant safety risks, such as heavy equipment and repetitive movements that can cause musculoskeletal injuries. The automation of manufacturing processes in the metalworking industry will reduce the amount of hazardous or repetitive work that these employees must perform.

   For example, a company could use a six-axis picking robot that can repeatedly bend or stretch to move materials around a metal manufacturing plant. Another company may use a collaborative robot (cobot) capable of tending machines or supporting a worker performing tasks such as adjusting metalworking machinery or taking measurements. The big advantage is that these robots do not get bored or tired during the course of the day, reducing the risk that fatigue could lead to a safety incident or injury.

   Even if an automation solution does not completely eliminate a task or replace a worker, it can help protect people from some of the safety hazards associated with metal fabrication work.

2. Reduction in labour costs

   Metal manufacturing faces a tight labour market, with hiring cycles becoming longer and the average cost of labour continuing to rise. In addition, rising labour costs in India and China are making offshore outsourcing expensive and therefore less attractive. Offshoring operations and investing in more robotic equipment can help reduce labour costs.

   The automation of manufacturing processes in the metalworking industry can reduce the overall cost of manufacturing metal products. A robotic welder could reduce the amount of labour required to complete welding tasks. This could lower overall production costs and make the workshop more flexible because machines do not need regular breaks and are available at all times, which also makes scheduling and work planning easier.

   Whether the automation of manufacturing processes in the metalworking industry replacing human workers rather than supporting them, can make sheet metal manufacturing much more cost-effective. As the price of labour continues to rise, along with the cost of resources such as necessary raw materials, reducing expenses will become an even more important advantage of automation for manufacturers.

3. Minimise waste

   If configured and programmed correctly, the automation of manufacturing processes in the metalworking industry will always produce parts or products with the correct tolerances. The system can automatically notify plant personnel if the process deviates towards the upper or lower tolerance limits, allowing them to take swift action to keep manufacturing running smoothly.

   Some tools, such as 3D printers for metal fabrication, can also leverage the advantages of additive manufacturing to reduce waste. These tools only use the materials necessary to create a new part, so they can minimise the generation of scrap, shavings, and other elements that a workshop would normally have to reuse.

   At the enterprise level, robotic process automation, AI analytics, and other automated tools can improve administrative processes to reduce waste. These trends, coupled with robots, can help streamline plant operations significantly.

   A business process automation solution can help managers bring together the company's information systems. These tools can also automate repetitive digital tasks, such as generating invoices, estimating budgets, and organising important files or emails.

   Managers can leverage this technology to streamline administrative work and reduce the risk of administrative errors. This helps reduce waste that can occur due to errors such as excess raw material inventory or miscommunication with customers.

4. Improving product quality

   Automation solutions can improve the overall product quality of a workshop. Automated metal fabrication machines are extremely consistent. Proper supervision and management allow them to operate for multiple shifts without diminishing productivity or consistency. As a result, workers can rely on the equipment to produce the same results every time they use it.

   In contrast, it is normal for the quality of products manufactured using manual processes to vary slightly, as worker fatigue, shift changes, and varying skill levels affect the consistency of the process. Over the course of a day, workers can become tired, make mistakes, and allow errors to creep into the production process.

   The solutions of the automation of manufacturing processes in the metalworking industry and quality control can make fewer mistakes. Those who do make mistakes tend to be more consistent, making it easier to identify and eliminate errors in the process that lead to lower product quality than those that occur intermittently.

   Manufacturers who need to improve the quality and consistency of their products can benefit significantly from the right automation solution.

5. Reduction in delivery times

   Most manufacturers face increasing pressure from customers to create products more quickly and with less lead time. However, reducing cycle and delivery times can be challenging, especially as supply chain instability makes it more difficult to place rush orders or source essential raw materials.

   Automation facilitates the reduction of delivery times in the workshop. It can reduce delays due to tasks that normally have to be performed manually, such as picking and placing, generating invoices, and ordering raw materials.

   Even if workers are unavailable to perform certain tasks, such as moving materials, the automation of manufacturing processes in the metalworking industry can guarantee continuity of production. The right solution can be an invaluable investment for companies that need to reduce cycle or delivery times.

If you believe that automation is a solution for improving processes in your company, find out how easy it is. How to select components for an automation project: 8 basic tips.

Conclusions of the automation of manufacturing processes in the metalworking industry

Changing market conditions, labour shortages and ongoing supply chain disruptions have forced metal manufacturing plants to adapt quickly.

The automation of manufacturing processes in the metalworking industry is often a powerful tool for companies that need to reinvent or optimise their workflows. The right solution can help manufacturers make their work safer, more economical, and less wasteful.

More sophisticated automation technology is becoming available thanks to technologies such as AI. Investing in these solutions now will enable manufacturers to take full advantage of these innovations as they become more accessible.

Industry 4.0 provides companies with technological solutions to optimise their processes. Discover the benefits of automation with robots and learn how to identify When to purchase a robotic welding cell for metalworking companies.