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There are some costs as well, and some things to avoid
if possible. The most obvious is the up-front cost of the
machine, but also the requirements for space, power, and
compressed air, among many other things. It would be
wise to consider who will be troubleshooting this machine
when it goes down, what components you will need to
stock as spares, and who handles changeover from
part to part. Standardization can also be key. Having a
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similar look and feel for the operator interface helps the
operator go from one piece of equipment to another more
Automated Gear Inspection
easily. Using the same PLC, motion controllers, and robots
Some processes are inherently unsafe for an operator or,
allows technicians to be able to troubleshoot more easily.

at best, very difficult to make safe. Automation can shield
Consolidating sensor types and/or brands makes stocking
the operator and the company from the costs of injury.
spare parts easier and helps the purchasing department
This can be for an unsafe environment, like a welding
get what is needed from fewer vendors.
process, or a repetitive stress injury risk. Light curtains,
safety laser scanners, and machine guards silently and
By far, the most important step in the process can be part-
relentlessly work to protect people and machines.
This is a long-term relationship and communication in
Automation also provides a way to give a better work
the process is everything. Does the company proposing a
environment. This can be done by reducing the noise or nering with the right company to automate your process.
solution understand your process? Is this something they
stress on the human body but also in ways you may not
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have a history of success with? How much experience
have considered. If you have an operator simply loading
do they have? Most importantly, are they trying to create
and unloading a machine all day, a portion of that labor
a stable, reliable, repeatable process? It can be tempting
can go toward other tasks, accomplishing more with
to focus on speed, and in some cases, it is absolutely
the same number of employees. If the operator is highly
required; however, keep in mind that reliability is more
skilled, you can leverage automation to use that person’s
important as it does not matter how fast you make scrap.
talent in more engaging and productive ways, making you
Finally realize that you will learn more about your process

and the operator more satisfied with the work being done.
than you expect. You will need to establish tolerances,
times, speeds, and many other parameters that you previ-
ously took for granted. You will notice part to part variation
more since the automation will need to accommodate it.
You will understand the details of the process more since
every step is now defined to be in a specific order and

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done in a specific way. This greater understanding can

lead you to be able to further refine the process, remove
unnecessary steps and realize what is more critical.
Motion Simple has automated many different processes
for many companies over the course of 25+ years. We
would be happy to examine any processes that you might
be interested in automating and offer you a solution.
For more information contact the author, Dave Holden
Dave Holden
EDM Today Magazine CONTACT EMAIL WEB EDM Today Magazine
EDM Today Magazine
Motion Simple
Concept of Robot Loading an Oven, Formerly a Fully Manual Process
https://www.motionsimple.com/
PHONE
MACHINES SUPPORTED
LOCATION
COMPANY
EDM
Support, Inc.
McNamee
Sinker, Small Hole
Elox, ERM, Xermac, EDM
Derek
EDM Zap Sugar Grove, IL 630-248-7068 Larry edmsupport@aol.com www.edmcorner.com Agie Wire, CHMER Wire,
www.edmzap.com
Montgomery, IL
info@edmzap.com
630-852-1699
Solutions, Belmont
Parts, Inc.
Kleinschmidt
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