5 Foundry Automation Misconceptions, Debunked
Within the foundry industry, resistance to change is high. Many adhere to deeply ingrained practices and are, amid the onslaught of new automated technologies, wary of falling prey to shiny object syndrome.
While this approach can be prudent, it can also hold foundries back from scaling, pursuing new revenue streams, or remaining competitive among their peers. Manufacturing is growing increasingly more automated – and the foundry industry has begun to adopt new technologies more aggressively. Because of this, those who fail to make strategic long-term investments in automation now may struggle to compete in the coming years.
As manufacturers of electromagnetic (EM) pumps – a form of casting automation – the CMI Novacast team hears, and is sensitive to, the concerns foundries have about automation. Despite the validity of some of these concerns, misunderstandings about automated solutions, in general, and EM pumps, by association, abound.
Here are the most common misconceptions we hear about foundry automation and EM pumps, debunked.
1. It Requires a Total Overhaul
Many foundries believe that automating their operations will necessitate a complete – and synchronous – overhaul of their existing equipment and processes. In truth, the scope of work is rarely all encompassing – and almost never occurs all at once. For the vast majority of foundries, full automation is achieved by making incremental adjustments and strategic investments over a multi-year period. Often, foundries focus on individually automating the following processes:
- Melting, with a reverberatory furnace or stack melter
- Molding, with 3D printer molds, robotic mold mills, or automated molding machines
- Casting, with an automated ladle, robotic ladle, or EM pump
The “right” sequence of investments will vary by foundry. Generally, foundries should seek to improve the worst, first – then work backwards from there. This approach may require some amount of engineering or customization, but the benefits are nearly always worth the effort.
For example, if a foundry elects to automate its casting line first with an EM pump, but uses a furnace that isn’t immediately compatible with the pump, the furnace may be modified. By investing in one piece of automated equipment – and altering an existing piece – the foundry can immediately enjoy the benefits of EM pumps, including:
- Increased throughput
- Maximized yield
- Reduced turbulent flow and higher metal quality
- Improved employee retention and recruitment
2. It Takes Up Too Much Space
Floor space is a premium at foundries – and many are concerned that automation equipment will eat up a disproportionate amount of that valuable space. While it’s true that some automation equipment requires more space than manual equipment, not all does – there is a plethora of solutions on the market, designed to work in a wide range of foundries.
EM pumps and their related systems, for example, require a modest amount of space. The pump, itself, sits inside the furnace, and the complementary equipment – a preheat oven, launder and control panel – have a small relatively small footprint. And, when it comes to casting automation, specifically, EM pumps take up a fraction of the space needed for robotic ladles.
If space is still a concern, consider productivity by square foot. An automated workflow can significantly increase throughput – and an automated end-to-end process can increase productivity by triple digits. Because of this, automated equipment uses space far more efficiently than manual equipment.
3. It’s Too Maintenance-Intensive
Many fear that automated solutions demand an outsized amount of maintenance. The truth is this: maintenance issues are unavoidable – regardless of the equipment used. While some automated solutions require more upkeep than their manual counterparts, others are relatively hands off – and some are even less maintenance-intensive in the long-run.
Consider the issue from this angle: workforce maintenance versus equipment maintenance. Foundries that rely on manual processes are dangerous places. A foundry that depends on employees to hand ladle molten metal must spend time protecting those workers from the injuries that inevitably result when molten metal is repeatedly hoisted across a foundry floor. It must also devote resources to encouraging employees to stick it out, regardless of the harsh working conditions.
On the other hand, a foundry that automates casting with an EM pump only needs to be concerned about maintaining the equipment. Because EM pumps move workers away from molten metal – and make foundries far safer overall – fewer resources and less time needs to be expended safeguarding and retaining workers. When considered from this angle, EM pumps and other forms of automation that make foundries safer, require less active upkeep than fully manual processes.
4. It’s Too Technically Complex
Most automation equipment leverages technology that is new to many foundries. Because of this, some are concerned they don’t have the capacity to handle increased technical complexity. While complexity does, of course, vary from solution to solution, nearly every piece of equipment is teachable – and learnable.
EM pumps, for example, are relatively easy to maintain and troubleshoot with some practice. Learning to use an EM pump is a little like learning to drive a car: like a car, the pump is a technical piece of equipment that takes time to understand and has rules and best practices. But, also like a car, an EM pump is a highly learnable piece of technology that nearly anyone can use.
5. It’s Bad for Employees
Many foundries equate automation with job loss and displacement and are concerned about the impact new technology will have on their workforce – and organization, by extension. In reality, thoughtfully implemented automation benefits both employees and their employers.
Foundries that rely on manual processes often put employees at risk of overexertion and burns. Many automated solutions move employees away from dangerous tasks – and make foundries safer, overall. When, for example, hand ladling is replaced with an EM pump, workers are no longer required to stand over vats of molten metal for hours on end.
In addition to making foundries less dangerous, EM pumps and other automated solutions give workers the opportunity to upskill. By learning how to use new technologies, workers gain technical, marketable, 21st century skills that position them to assume higher wage positions with more opportunities for growth.
These benefits extend to employers. Foundries that offer a safer environment and more desirable jobs have an easier time retaining and recruiting employees. And, when members of staff acquire more diverse and advanced skillsets, it’s easier to promote existing employees and fill roles that are traditionally challenging to hire for.
Automate Casting with Ease
Since its founding in 1981, CMI Novacast has supplied foundries with EM pumps and related systems, including heated launders, preheat ovens and control systems, to alleviate common casting problems. Implemented alone, or in conjunction with other automation equipment, CMI Novacast EM pumps supercharge production, improve the quality and finish of metal, and help foundries retain and recruit employees.
For more information about EM pumps or foundry automation, speak with a CMI Novacast factory expert or download our guide, A Guide to Automating Your Foundry & Casting Process.