Getting Started with Automation: Where to Begin

Whether you work with small or large die casting machines, the days when automation was just a nice-to-have are gone. This doesn't mean your entire facility needs to be filled with robots, but everyone should be looking at ways to integrate automation into the casting process. It's not just about adding automation; it's about improving processes to increase profits and production efficiency. The casting process involves managing critical parameters with every shot, and automating these requirements is crucial for producing high quality castings. This is especially important for competing against offshore foundries and ensuring the sustainability of your company. All business owners are aware of the challenges of hiring experienced decasters. This isn't unique to the casting industry; it affects the entire global workforce when it comes to skilled trades.

Automation does more than simply reduce the number of workers needed. It also creates opportunities for higher-skilled operators who are more likely to advance and remain with your company, contributing to long-term growth. Many die casting companies now use robots in their foundries to tend to the die cast machinery, ladle the molten metal, spray mold release, and trim excess metal. Consistent process timing is essential for producing quality castings, and deploying robotic technology in the foundry can help ensure this consistency. However, many companies have never automated due to fears of high costs, lack of technical experience, and the potential nuisance and time-consuming setup for short-run jobs.

So, how can you decide where automation is needed the most in your business? To determine which areas need the most attention, we suggest closely examining your bottlenecks, waste drivers, defects/scrap, and quality issues. Adding automation does more than just increase outputs and handle hot and heavy loads; it ensures consistent quality by minimizing human intervention.

Manually removing parts from the die casting machine can be very challenging for an operator, depending on the size and weight of the casting. The parts are extremely hot, and depending on the condition of the tooling and the machine's alignment, the part and gate may have sharp edges from flashing that can pose problems for the operator.

Utilizing a robot to automatically remove the casting and gate significantly reduces the risk of injury to the operator and improves casting quality by maintaining consistent cycle times. Automating the extraction process helps maintain continuous cycle times, which in turn greatly enhances productivity.

Pouring molten metal is a strenuous job that requires a steady hand. The operator must pick up and pour the molten metal while also handling the hand ladle bucket, which puts undue stress on the operator trying to maintain a quoted cycle rate repeatedly. A robotic ladle can ensure accuracy and is a good alternative to human workers for pouring molten metal. Robots can be optimized to pour the same quantity of molten metal each time. A robotic ladle can skim dross and pour molten metal much faster than a human, eliminating turbulence and reducing the chances of spills. This advantage also applies to loading inserts and extracting the solidified castings.

Casting dies require a lubricant film to be sprayed over their surface while open. Consistently applying this lubricant can be challenging for humans due to poor access and obscured visibility from mist, leading to quick fatigue. This may result in uneven application of lubricant, causing uneven die cooling and potential issues with the casting. While an experienced die caster can make the process seamless, an inexperienced operator may cause serious casting defects and potential tool damage.

Using robots is beneficial in such cases, as they consistently follow a programmed path. Many experienced die casting
companies have already embraced and adopted these advanced technologies. This includes custom-designed spray
manifolds that apply lubricant to critical casting areas for the desired amount of time, ensuring consistent cooling and
improved metal flow with each cycle of the die cast machine.

Unnecessary overflows, flashes, and risers are inevitable in casting and should be removed before the die cast pieces move to downstream
operations. A robot can use a grinding wheel or other cutting tools to trim away the excess metal or load the casting into the trim tool for trimming or de-gating. In high volume cells, multiple robots can efficiently accomplish various tasks, including loading, unloading, quench
tank cooling, flatness checking, and packing.

The industrial world is undergoing significant technological changes, which are increasing the demand for premium quality products and
services. This demand can only be met through high levels of productivity. As a result, global industrial companies are increasingly turning to automation enhance their skilled workforce, reduce operational costs, increase productivity, quality, process consistency, and safety.

Fortunately, proven and reputable automation solutions are widely available for both die casting and foundry automation applications.
The hard part will be evaluating your operation to determine which process needs the most assistance. Applying Lean manufacturing principles would be a first step forward in evaluating your operation for automation enhancements to improve processes, increase productivity, and reduce costs.

The industrial world is undergoing significant technological changes, which are increasing the demand for premium quality products and services. This demand can only be met through high levels of productivity. As a result, global industrial companies are increasingly turning to automation enhance their skilled workforce, reduce operational costs, increase productivity, quality, process consistency, and safety. Fortunately, proven and reputable automation solutions are widely available for both die casting and foundry automation applications. The hard part will be evaluating your operation to determine which process needs the most assistance. Applying Lean manufacturing principles would be a first step forward in evaluating your operation for automation enhancements to improve processes, increase productivity, and reduce costs.