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Common Misconceptions About Grinding Automation

Even as more manufacturers invest in grinding automation, the technology remains the subject of misconceptions. Many manufacturers believe that robot loaders and other automation tools are prohibitively expensive, time consuming to implement and will not work with their existing machines, according to our recent Grinding Automation Survey. 

Whether your primary motivation for pursuing grinding automation is to address an inefficiency in your shop, or it’s a requirement for a prospective new client, or it allows you to expand into a new segment, this journey can lead to process optimization, particularly for those shops that lack an adequate understanding of their overall equipment effectiveness (OEE).

Let’s dispel and debunk some of the common misconceptions associated with grinding automation. For a broader look at the state of automation in manufacturing, see our ”State of Automation” white paper.

Economics and ROI

Misconceptions: The price of entry into automation is too high; and it only works for high-volume production.

Realities: Whether you view ROI from a lens of hourly costs of robotics vs. operators, the return of CAPEX or piece rate/cost per part, the value of grinding automation quickly becomes apparent. Not only is it effective in optimizing your human capital, automation achieves greater throughput, higher part quality and increased productivity for lower costs.

According to calculations based on data from the Robotics Industries Association, installing a single flexLoad system from UNITED GRINDING North America and basic tooling instead of hiring an operator will save you more than $1.5 million in labor costs and nearly $500,000 in productivity savings over 15 years.

Automation solutions have more predictable outcomes and produce higher quality on a more consistent basis, which helps manufacturers optimize HMLV production, even when that mix must be managed by one machine.

Technical Applications

Misconceptions: Robotic loaders are difficult to integrate with cylindrical grinders; and robots are not flexible.

Realities: Integration was more challenging when OEMs were more siloed and focused on specific processes and operations. OEMs such as UNITED GRINDING North America and FANUC have for some time produced built-in automation interfaces, largely eliminating the need for complicated integration efforts. For example, STUDER grinders are engineered for automation.

FANUC controls often enable manufacturers to link their automation with ERP, SCM and MES software, further enhancing OEE.

Furthermore, robotic manufacturing capabilities have greatly expanded in recent years to include 3D vision sensors, adaptive grippers powered by machine learning algorithms, fixtureless designs, and automatic tool changers.

Implementation, Integration and Support

Misconceptions: Automation is complex to program and operate; and it requires a lot of training and support.

Realities: UNITED GRINDING’s consultative design and implementation approach has yielded easy-to-use HMIs and controls. A menu-guided teaching program and a hand-held pendant make it possible for operators without any programming experience to easily set up robots and create new automation routines. Part numbers, grinding programs, home programs, drawer selection and cycle status are all easily accessible.

UNITED GRINDING’s automation operation is based in central Ohio, putting it in close proximity to manufacturing hubs and making it easy for our team of engineers and service experts to collaborate with our customers on design, implementation, and ongoing training and service.

Labor and Infrastructure

Misconceptions: Automation eliminates shop-floor operator jobs; and it requires a larger footprint.

Realities: Research shows automation does not cause a net job loss. Automation and its repeatability create a cascading series of productivity benefits, including a lower price per part and increased throughput.

Robots handle repetitive, manual tasks such as loading and unloading, gauging and conveyance. With automation, operators can oversee multiple machines in the production cell, creating additional value. Automation also helps manufacturers address future workforce needs by offering the kinds of robotics jobs that technically minded young people prefer.

Most manufacturers must contend with limited amounts of shop floor space to accommodate automation, so OEMs have responded with space-efficient machines and innovations such as overhead gantry-style robots.

How Grinding Automation Will Work for Your Shop

Manufacturers understand that staying ahead of the competition requires optimizations that can be realized with automation technology. But who will install the automation system? Who can be trusted to service a custom solution? Where can manufacturers go with issues? How can they realize the benefits of automation with the fewest headaches?

UNITED GRINDING Automation Solutions is a one-stop for your questions and concerns. The automation process begins with a consultative approach with application engineers. It includes installation, training, applications support, preventive and predictive maintenance, parts and repair services available locally or remotely 24/7.

Learn more about UNITED GRINDING’s Automation Solutions and start putting automation to work for your shop.

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