Our Sites

Cobot-powered stamping automation improved by training

Cobots perform machine tending, inspection, and palletizing for sheet metal manufacturing

cobot automation in sheet metal forming

Siouxland Fabricating Inc., a small custom fabricator, was struggling to find workers for machine tending. The company deployed a cobot on a high-mix/low-volume application. A cobot picks up parts from the left pallet, places them in the machine, actuates the machine, then palletizes the finished parts on the right pallet. The deployment filled a labor gap, cut cycle times in half, and improved quality. Universal Robots

The manufacturing skills gap predates the COVID-19 pandemic by several years. The stamping industry has had difficulty attracting young people to manufacturing jobs and the baby boomer generation of workers is retiring. The problem has accelerated rapidly in today’s uncertain post-COVID economy.

The impact is visible across all manufacturing positions from general operatives to production managers. A sobering report from Deloitte and The Manufacturing Institute found that if nothing is done about the manufacturing skills gap, it could cost the U.S. economy alone as much as $1 trillion.

One way that companies can immediately address the stamping press skills gap is by deploying collaborative robots to automate the roles and shifts that are hard to fill.

Cobots Aid in Stamping Automation

Collaborative robots, or cobots, are used by stamping manufacturers to boost productivity, improve quality, and enhance ergonomics. Major drivers of cobot adoption are a lower total cost of ownership (TCO) than traditional automation and high usability. However, the most significant force driving adoption is that cobots provide a cost-effective way to overcome the labor crisis facing companies of all sizes and types.

In general, cobots empower stampers of all sizes to automate press operations easily and effectively. Cobots can take care of the repetitive tasks, enabling companies to hire previously unfillable roles and improve workplace ergonomics.

Cobots are powerful platforms for performing all sorts of applications from inspecting, machine tending, palletizing, screwdriving, and machining. Cobots are being deployed for stamping press tending on night shifts as well as day shift pick-and-place tasks designed to improve ergonomics for human workers.

Not all cobot-based systems are the same, however. So, what are the key considerations to keep in mind when selecting a cobot-powered stamping automation system? And what steps can you take to improve the success of your cobot deployment? Training is key.

Training Key to Successful Stamping Automation

You may be anxious about your ability to deploy and manage stamping automation successfully. It’s true that traditional stamping automation has a reputation for being complex, requiring a lot of time to deploy. This can be off-putting and especially intimidating for those who are new to automation.

The best way to lessen those anxieties and help you decide whether cobot-based stamping automation is a good fit for your company is to get some hands-on experience with a cobot system. Almost invariably, these initial fears regarding complexity fade away when people come face-to-face with cobot programming processes.

When selecting a cobot, look for a provider that comes with easy access to hands-on demonstrations with their engineering and production teams. Not only will this quell fears around cobot complexity, it also will provide an opportunity for the manufacturer to answer questions about the details of the process you are trying to automate.

Siouxland Fabricating installed its cobot on a mobile platform

Siouxland Fabricating, Rock Valley, Iowa, installed its cobot on a mobile platform to quickly move it between stations. Universal Robots

In addition, online e-courses, simulators, and training videos can provide a user with experience too. Content is available for end users of all skill levels, from e-books1 that introduce key concepts and video tutorials that guide you through the details of an application deployment.

Training Specifics

Training differs depending on your cobot provider, but it’s a good idea to set some minimal expectations, such as free online resources that guide you through the process of deploying cobots on specific applications and offerings that include hands-on training.

If your cobot provider offers hands-on training opportunities, take them. There, you can expect to be introduced to cobots, key safety concepts, and you will likely program your first simple cobot application on the first day.

One of the attractions of cobots is they are easier to program than traditional automation, thereby enabling end users to program the automation in-house.

For example, some cobots can be programmed simply by guiding them into position manually and then completing some simple steps. These steps include adding waypoints, a teach pendant, or inputting parameters via desktop, laptop, or smartphone. For example, for many cobot-based palletizing applications, end users simply select the pattern they want to use and the cobot takes care of the programming details. Due diligence on usability will save your company a lot of time down the line.

Training also is the best way to ensure buy-in from (and provide reassurance to) end users. From the managerial perspective, training workers on cobots is a great way to upskill and retain existing staff. Cobots also have a “Wow!” factor that can make it easier to hire young people.

Stamping Automation Should Start Small

Starting with a simple application ensures a quick ROI. It’s advisable to start with a straightforward application such as a simple pick-and-place operation. The cobot picks up an item, feeds it into a stamping press, then picks up the finished part and places it in a pre-determined location.

Later, experiment with more complex applications, such as a task that involves part feeding and a palletizing process. The cobot gathers several parts at a time as they come off the press and palletizes them. This type of application may require slowing down the press line during palletizing, then bringing it back up to speed when palletizing is complete. Some cobots come with built-in palletizing wizards that only require the user to enter part size and a few coordinates; then the cobot controller works out the grid pattern.

Put the cobot to work. If one stamping cell does not have the workload to justify the cobot investment, consider placing the cobot on a mobile platform so you can move it easily between different stations.

Safety Considerations

Cobots have numerous safety features designed to enable humans and automation to work safely in the same environment. Cobots are force- and speed-limited robots, which means that they run slower than traditional industrial robots—this is what makes cobots safe to deploy around humans.

cobot picks parts from the part-feed cart

Olympia Chimney, Scranton, Pa., a leading manufacturer of chimney venting systems, hired Mid Atlantic Machinery Automation LLC to integrate Universal Robots' UR10e cobot to a notching press. The cobot picks parts from the part-feed cart, then inserts the part into the notching press and fires the press to create the notch. Mid Atlantic Machinery

Some deployments incorporate light curtains or laser scanners, which can detect when a human enters the workspace and limit the cobot’s speed accordingly. They will come to a complete stop if a human comes within a certain range of, or makes contact with, the cobot. This is not to say that cobots are inherently safe. It is essential to carry out a risk assessment before integrating automation into your processes. Integrators can do that for you. And remember that different cobots provide varying levels of safety, so be sure to research your options.

A good cobot safety reference is safearoundrobots.com, a free digital toolbox funded by the European Union's Horizon 2020 research and innovation program. The program is a central repository of information and guidance regarding risk assessments, safety directives and standards, and the safety best practices that apply to collaborative robot application deployments. It also includes information on validation protocols, case stories from users in manufacturing, and up-to-date cobot safety-related publications.

Integration Considerations for Stamping Automation

Should you get an integrator or not? If this is your company’s first automation project, then almost certainly it would be beneficial to have an integrator help with the initial deployment. Not only can they take care of any technical signalling issues that could arise, but they also can provide additional hands-on training to supplement training provided by your cobot manufacturer.

If you decide to get an integrator, look for a reputable integrator with experience automating processes for stampers. One of the important applications is getting the signalling right between the automation and the stamping press.

If your efforts to deploy automation in-house are unsuccessful, don’t be afraid to call in an integrator.

Find a Champion

It’s absolutely mission critical to have an ambassador. Identify someone within your organization who can take ownership of the project and champion the system. Without a project champion or an ambassador, the likelihood of success is reduced.

About the Author

Joe Campbell

Senior Manager of Applications Development

5430 Data Court, Ste. 300

Ann Arbor, MI 48108

844-462-6268