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CORNER
EXPERT’S

Automation does come in many different fl avors, so benefi ts can be realized for the processing of low volume/high
mix parts (job shop) or by high volume/low mix parts (production). In the EDM world, the most common automation
method is to load and unload parts in and out of the machine using a standardized Work Holding Pallet system. This
standardization and palletizing of the tooling helps to minimize processing variables through the use of off-the-shelf
EDM tooling chucks that provide location and setup repeatability, and this tooling also establishes a consistent work
holding interface that an automated robot arm can access.

Implementing automation is like the next
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level of a video game…things may seem
harder or more complex and confusing
at fi rst! While it is human nature to fi ght
or fear the unknown, once we understand
and adapt to meet the next challenge,
we learn new tricks and may shift our
skillsets to achieve a new outcome.
A shift in skillsets and routine defi nitely
occurs with automation, as the opera-
tor’s world may be turned upside down!
An operator must openly embrace new
controlled process methods and apply
their abilities differently with automation.
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A few examples are the need for stricter
programming, methodical and consistent
process planning, and the use of ma-
chine/robot scheduling functions to drive
the system. Automation’s fl ow requires
a change in the operator’s actions, as
tasks must conform and be consistent to
support the means to transfer the parts
and programs to the Robot System.

Critical Steps to Automation: 3 Photo Courtesy Erowa Technology Inc.
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Standardize Part Setups and Fixturing
Identify a Bottleneck Process in the Shop
1
(Improve effi ciency)
(Find your weak spot)
a. Establishing standardized and common work
a. Is there an area or process that is always behind
holding methods can enhance quality while
that restricts your fi nal output?

reducing setup time.

b. Investigate and determine the reasons why a
specifi c operation is a bottleneck.
b. Tooling standardization can minimize idle time and

improve machine utilization (the operator has a

limitation?
i. Is there a machine or manpower capacity 4 common and consistent playbook to work from).
ii. What is the effective utilization of the
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equipment in this area?
Plan, Plan, Plan! (Where are you now, and
what are you working towards?)
a. What are your machines and limited human
Establish a Stable and Repeatable Process

resource capabilities?
2
(Controlled and consistent results)
b. Establish a vision for your operations and apply
a. Is the equipment running but not yielding the

methods to maximize unattended machining and
quality desired (producing scrap)?

consider automation to achieve greater unattended

operation.
b. Are the parts programmed, set up, and machined
the same way each time?

c. Consistent optimized processes ensure
quality control and minimize scrap.

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