SW North America, CNC Machines and Automation
Published

Overcoming Barriers to Machine Shop Automation

Industrial automation using robots has improved productivity for operations large and small — so why do some manufacturers shy away from it?

Share

Person working with industrial automation

Embracing automation sometimes means changing shop processes. Photo: Getty Images

I have been a great advocate of industrial automation, including robots, for years. I have always seen this technology as the key to being competitive in the marketplace. Over the years, I have become more and more frustrated that many organizations are not embracing automation and robotics technologies. In machine shops, the resistance seems especially high. When I ask shops about their resistance, I often get the same answer: Automation does not fit into our processes.

While manufacturers have good reasons for implementing the processes they do, my natural response to this is, “then change your processes.” 

There are a few barriers to automation that I believe lead people in the industry to keep this mindset. Firstly, robotics are not as effective when we expect them to exactly imitate human motion. Thinking of robotics in terms of human motion is a natural tendency, especially with Hollywood portraying robots as indistinguishable from humans. Maybe down the road, that will become reality, but for now we must plan our processes around the actual strengths and capabilities of robots.

One main advantage of robots is that they can repeat the same movements continuously without fail. They also won’t slow down during the day and don’t require breaks. This is their strength. We therefore have to plan their movements ahead of time and according to their strengths, not the strengths of human workers.

Another difficulty of embracing automation lies in the variability of material sizes used on the shop floor. Robots are very productive when using a common size of material, but machine shops often need to use differently sized materials to minimize the amount of machining. This leads to high variability in raw material sizes. Constant changeover on robots and fixtures due to material variability is not very productive, and can slow down processes — the opposite of what we want in an automation solution.

To overcome this, it’s ideal to make parts out of similar material sizes, of course. If that’s not possible, batching parts that are made with the same size of material is helpful. In my experience, on smaller items, the material cost is not typically as important as throughput. Throughput reduction causes bigger cost savings and therefore higher profits then the cost savings that come from minimizing the material size. Strategies for using the same material for various items help give longer run volumes and therefore robots can be more easily integrated. Using a common size of material leads to greater productivity with automation.

Finally, robots are very effective in situations where common fixtures are used to hold parts. Often, shops use many different fixtures to hold various sizes of material — unfortunately, this does not play to the strength of robots. This is a great point at which to rethink processes. To simplify automation integration, the objective is to load common piece of material onto a common fixture. Manufacturers should consider finding a fixture that will hold numerous parts done repeatably.

I realize that coming up with strategies will take time and effort, but they enable large operations and smaller job shops alike to be competitive into the future. Automation and robotics are also key to addressing the shortage of skilled worker. We can sit here and complain that we cannot find enough workers or we can implement a strategy to help our current and future workers become more productive and competitive.

The first step to implementing robots and automation is saying “yes” and embracing the change, adjusting processes as necessary. Many companies are doing this with success. Denying the potential of automation is like sticking your head in the sand. The world will continue to move around you and you will be left further behind.

The point of using automation is to make production simpler and more repeatable. It is about saving labor and being more productive. It is about giving employees tools and strategies to compete at a higher level. I truly believe that automation and robotics will be the standard in machine shops in the near future, and I already see this on the horizon.

I am hoping that machine shop owners find the courage to implement robotics and automation because it brings a much brighter future companies and its employees. That is how I see it from the shop floor!

SW North America, CNC Machines and Automation
TIMTOS
Koma Precision
More blasting. Less part handling.
Paperless Parts
VERISURF
High Accuracy Linear Encoders
World Machine Tool Survey
Innovative Manufacturing for the Medical Industry
DN Solutions
PMTS 2025 Register Now!
SolidCAM

Related Content

Basics

4 Steps to a Cobot Culture: How Thyssenkrupp Bilstein Has Answered Staffing Shortages With Economical Automation

Safe, economical automation using collaborative robots can transform a manufacturing facility and overcome staffing shortfalls, but it takes additional investment and a systemized approach to automation in order to realize this change.

Read More
Automation

Automating Part Programming Cuts the Time to Engaging Work

CAM Assist cuts repetition from part programming — early users say it could be a useful tool for training new programmers.

Read More
Five-Axis

Fearless Five-Axis Programming Fosters Shop Growth

Reinvestment in automation has spurred KCS Advanced Machining Service’s growth from prototyping to low-and mid-volume parts. The key to its success? A young staff of talented programmers. 

Read More
Automation

Four-Axis Horizontal Machining Doubles Shop’s Productivity

Horizontal four-axis machining enabled McKenzie CNC to cut operations and cycle times for its high-mix, high-repeat work — more than doubling its throughput.

Read More

Read Next

Sponsored

The Future of High Feed Milling in Modern Manufacturing

Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.

Read More
Toolholders

Rego-Fix’s Center for Machining Excellence Promotes Collaboration

The new space includes a showroom, office spaces and an auditorium that will enhance its work with its technical partners.

Read More

5 Rules of Thumb for Buying CNC Machine Tools

Use these tips to carefully plan your machine tool purchases and to avoid regretting your decision later.

Read More
SW North America, CNC Machines and Automation