In light of the fourth industrial revolution’s significance in today’s industrial setting, automation is an unavoidable route for industrial manufacturers. With the application of computer-aided systems, robotic operators, automated equipment and M2M communications, the efficiency of manufacturing is expanding to new horizons. Statistics show that 38% of employees in the industry of automated workflows are already robots, and experts predict that this figure will double by 2025.

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Ultimately, automation provides predictive, reliable workflows with consistent quality outputs. At AMP Metal, we use automated solutions to ensure ideal metal outputs free from quality defects and durability deviations. We offer the most advanced, customised solutions in automated metal processing that are dedicated to satisfying every client.

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There are four milestones involved in transforming traditional metal manufacturing to automated metal processing: standardisation, digitisation, information prognosis and full automation. Each milestone ensures a higher degree of process predictability, conformity and excellence.

In the following section, we will dissect the advantages of automated metal processing and explain the steps in the journey of the transformation from manual metal fabrication to automated manufacturing workflows.

Benefits of Automated Metal Processing

Automated technology has revolutionised metal processing. With the help of computer aided systems and robotic equipment, modern metal fabrication has the following strengths:

• Makes metal processing more efficient by reducing unnecessary waste. 
• Saves energy since it skips the step of energy-channelling before every start by working continuously.
• Offers a superior quality of work to that achieved with traditional methods.
• Results in greater precision thanks to the robot operators and CNC system.
• Allows operators to avoid repetitive, tedious tasks so they can instead focus on complex tasks that require skill.
• Saves time not only because the robotic operators move faster to the operation points, but also because  the pre-programming schedule can save deciding time.
• Allows manufacturers to save material and energy and lower the production costs. 
• Benefits employees by greatly increasing safety in the working environment.

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4 Steps to Automating Your Metal Processing Workflow

The journey from traditional metal processing to automated metal fabrication can be divided into four different steps. In each step, manufacturers have the chance to evaluate previous work procedures and audit their current decision-making practices to ensure an ideal workflow going forward.

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Step #1: Implementing Standardisation 

The first step in automation is implementing standardisation practices. To maximise the potential of automation, manufacturers have to examine and analyse their existing workflow, identifying what works optimally and what doesn’t. This helps clear away any redundant activities in the workflow and re-route processes towards a new manufacturing plan with minimal waste and peak performance. 

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Standardisation is crucial for automation because consistent practices ensure a much more efficient process. Standardisation practices like Six Sigma eliminate the deviations created by manual operations. Ensuring a consistent and practical approach helps save unnecessary investment while producing profitable results, since all the remaining procedures are essential. In turn, this will result in a problem-solving internal mindset that enforces upstream revisions.

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‍Step #2: Leveraging Digitisation

To create a successful business strategy with automation at the forefront and apply standardisation to secure optimal workflows, it’s necessary to record and store data. A well-established, high-level database is key to storing data and monitoring workflow performance. In today’s digitally-advanced industries, we can precisely and efficiently track, store and monitor data like timestamps, deficiencies and undesired variations, and with data accuracy, digitisation helps find the root causes of problems or malfunctions.

While digitised data collection and monitoring is significantly more efficient than manual, it also provides much more insight in terms of the context behind each piece of data. Data context helps analysts better understand situations and adjust the system accordingly. 

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Step #3: Processing and Information Prognosis 

Information processing makes it possible to leverage all digitally collected data and contexts to form a knowledge base. This intelligence is customised based on the working material, machine models and operators. With continually documented data, it’s possible to make necessary adjustments in real time to maximise process performance. 

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After a systematic modification process, the knowledge gained can be applied in future prognosis, which gives manufacturers the advantage of being able to predict workflow performance, elevate process efficiency and avoid possible malfunctions and variations.

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Step #4: Empower Full Autonomy

The ultimate goal of industry 4.0 is to reach full autonomy, or “lights-out manufacturing”, with ultimate output generation through 24/7 operation. Reaching full machine autonomy will minimise potential obstructions caused by manual operation, enable large-scale machine-to-machine communication, amplify machine self-learning (adjust and learn by itself through every repeated action) and secure the production of smart machines that can diagnose issues without the need for human intervention.

Experts in different areas continue to work together to achieve full autonomy and fine-tune solutions for gaps where machines still cannot adequately substitute for human labour.  At AMP, we process every project with a strong problem-solving team of experts working aligned with highly advanced technology. From laser cutting and metal bending to robotic welding, our experience in automated metal processing secures superior outputs and delivers impeccable results.

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Related Searches

What is Automation in Manufacturing?

Automation in manufacturing refers to the process of replacing manual operations with machine and computer-aided systems. The goal is to enhance the efficiency of production, improve capability and reduce costs. There are three different levels of automation: fixed automation, programmable automation and flexible automation.

To learn more about automated metal processing and how it helps AMP deliver superior custom metal solutions, take a look at our recent blog post where we outline the four types of metal fabrication services we offer.

What is Automated Robotic Welding?

Robotic welding represents a cornerstone of the contemporary manufacturing industry. The key reason for this is the quality output robotic welding systems offer in short cycle times. Robotic welding uses a robotic arm in the welding process to assemble semi-products and furnish and maintain  the shaping result of metal processing.

Key Takeaways

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1. Automated metal processing is an essential step in the development of the metal fabrication industry. It benefits the business by improving work efficiency and creating a better working environment.
2. There are four steps involved in the automation process: standardisation, digitisation, information processing/prognosis and full autonomy. Each step requires manufacturers to examine their working method from different aspects to generate an ideal, highly productive automation plan.
3. Full autonomy is the goal that every expert works towards. It makes the manufacturing process more productive and saves time. With the development of machine learning, it is possible to minimise the participation of human labour.

Do you want to know more about how we apply automation technology in our metal fabrication services? Contact us today and learn more about AMP through a consultation. Our goal is to help manufacturers in aerospace, oil and gas, utilities and civil engineering optimise their manufacturing processes with our highly reliable custom metal solutions.