5 Myths About Foundry Automation Solutions, Busted
Metal casting is one of the world’s oldest professions. Within the aluminum foundry industry, resistance to changing deeply ingrained processes and practices is high – and skepticism about automated solutions runs rampant. Many prefer to rely on age-old practices than experiment with new automated technologies on the market.
While sticking with the status quo can be prudent, it isn’t always. Foundries that resist efforts to modernize may be held back from pursuing new revenue streams or scaling – and risk losing a competitive advantage. As manufacturers grow increasingly reliant on automated solutions, foundries that eschew technological upgrades may struggle to keep pace with their more forward-thinking peers.
Foundries that are on the fence about adopting automation might also feel overwhelmed by the number of solutions on the market. These include:
To help foundries prepare for the future – and dispel fears metal casters may have about technological advancements – here are five of the most pervasive myths about foundry automation solutions, in general, and EM pumps, specifically, busted.
1. Automation Equipment Eats Up Too Much Space
Many foundry managers are concerned that automation equipment takes up more floor space than they are willing to sacrifice. While some automated solutions do require slightly more space than their manual counterparts, not all do. There is a wide variety of solutions on the market, designed to meet a range of needs.
For example, EM pumps, which use electromagnetism to move molten metal from a furnace to a mold, are installed inside furnaces – and take up relatively little space.
Another way to approach the issue of space is by considering productivity by square foot. Automated workflows can supercharge production and, therefore, use space more efficiently than manual equipment.
2. Automated Solutions Are Difficult to Maintain
A major factor that holds many foundries back from investing in automation is the fear that automated equipment is too maintenance intensive. And, while effort does need to be expended to maintain automated solutions, the same can be said of any equipment. When compared to manual processes, some forms of automation can actually be easier to maintain.
As an example, consider the effort needed to maintain a workforce versus equipment.
A foundry that relies on workers to hand ladle molten metal assumes a fair amount of risk: the work is highly dangerous – the foundry likely struggles with recruitment and retention. Managers end up spending an inordinate amount of time protecting workers and keeping the foundry fully staffed.
But, if that same foundry moved workers away from molten metal by automating casting with an EM molten metal pump, they would no longer need to expend so many resources fighting employment battles. Workers and the foundry would, naturally, be safer – so the only concern would be maintaining the equipment.
3. Automation is Too Technically Complicated
Foundries that rely on manual workflows may be unfamiliar with the technology used to power automated solutions. Concerns about the technical complexity of the equipment are common. While some solutions are more technically complicated than others, nearly every piece of equipment is learnable. EM pumps, for example, are very easy to operate and maintain with some training and practice.
4. Automated Solutions Harm Employees
Across industries, automation is often viewed as being synonymous with job loss. While this can be true to some extent, automation equipment is a net positive for foundry employees – and their employers.
Foundries that depend on manual workflows put their employees at risk of injury and overwork. Automated solutions, like EM pumps, move employees away from the most dangerous parts of the foundry – and allow them to be reassigned to safer and more rewarding work. Instead of hoisting heavy ladles of molten metal for hours on end, employees are free to learn new technologies and gain marketable skills in the process.
Employees aren’t the only ones who benefit – employers do, too. It is easier to recruit and retain employees when work is safer and offers more competitive wages. Further, when workers learn new, technologically advanced skills, they can be promoted to roles that are traditionally challenging to hire for.
5. Automation Requires a Complete (& Costly) Overhaul
Many foundries are fearful of automating their processes because they believe that doing so will require a total overhaul.
The reality is this: hardly any foundry automates all of their workflows synchronously. Instead, the overwhelming majority make incremental, strategic investments over a several year period. Often, they will automate one workflow (melting, molding or casting) before moving on to another.
Foundries usually start seeing the fruits of their investment immediately. For example, foundries that automate their casting process with an EM pump can immediately enjoy benefits including:
- Lower scrap
- Higher throughput
- Maximized yield
- Reduced turbulent flow
- Higher metal quality
- Increased safety
- Improved employee retention and recruitment
About CMI Novacast
CMI Novacast has manufactured EM pumps that automate the movement of molten metal in foundry casting and non-casting applications since the early 80s. In foundry applications, CMI Novacast’s EM pumps improve safety, increase worker retention, decrease scrap, and improve metal quality. Because of this, the pumps increase yield and supercharge production, especially when combined with other foundry automation equipment.
Post Your Ad Here