How do you prepare for Automation?

Why CNC Automation?

A CNC machine is an investment. Yet in many production environments, it sits idle for much of the time, for example during breaks, between shifts, or at night. Often, the problem isn’t the machine’s capacity, but the availability of employees to load and unload workpieces.

Robotic Automation helps you get more spindle hours. This allows you to:

• Increase production with your existing machinery
• Continue operations in the evenings, at night, and/or on weekends
• Reduce repetitive tasks for operators
• Shorten delivery times
• Ensure more consistent production
• Easier to adapt to staff shortages
• Relieve operators of physically demanding work

1. Map out your current production process

Successful automation doesn’t start with the robot, but with your process. So first, analyze how you’re manufacturing today.

Ask yourself the following questions, among others:

• Which machines experience the most downtime?
• Where do wait times of bottlenecks occur?
• Which tasks are repetitive?
• Which parts are used regularly?
• At what times does the machine come to a standstill due to a lack of staff?

Also consider the material feed, quality controls, clamping devices, and the removal of finished parts, as these factors determine whether a process is suitable for automation.

2. Choose the right machine to automate

It is usually not necessary to automate the entire machine fleet right away. Start with an application that is straightforward and can deliver quick results.

A good first candidate is often a CNC machine that:

• Is reliable and technically stable
• Has sufficient production volume
• Regularly processes similar workpieces
• Has a predictable production process
• Could often produce outside of staffed hours
• Currently requires a significant amount of manual loading and unloading time

Both CNC lathes and milling machines can be automated. The best choice depends on the variations in workpieces, batch sizes, cycle times and available space.

A stable process is essential here. A robot repeats exactly what you instruct to do, but it does not solve fundamental problems in machine clamping of tool management. Therefore, first ensure that the process runs reliably without automation.

3. Select suitable workpieces

A common misconception is that automation is only worthwhile for large production runs. That notion has long since been debunked. After all, modern, user-friendly robotic solutions can also be cost-effective for smaller production runs or even single units.

Suitable workpieces have the following characteristics:

• They can be gripped safely and reliably.
• They fall within the robot's capacity.
• They can be positioned consistently.
• The machining cycle is stable.

Start with a relatively simple product. Once operators are familiar with the automation, you can add more complex parts, smaller batches, and greater variety.

4. Involve your operators from the start

Automation isn’t just a technical project. It’s also a change in the way people work. That’s why it’s important to involve operators, programmers, and production managers early on in the process.

They have hands-on experience and know where things can go wrong. Their input helps to:

• Select suitable workpieces
• Identify risks more quickly
• Improve work methods

Also, clearly explain why you’re automating. The goal is to help them make better use of their time and make their jobs more appealing. Operators can manage multiple machines and focus on more creative tasks. Ease of use plays a major role in this.

5. Prepare the work area

Automation must fit logically into your existing production environment. Keep the following in mind:

• Available floor space
• Access to the CNC machine
• Workpiece loading and unloading
• Safety zones

A compact solution can be important when space is limited. At the same time, the machine must remain accessible for daily operations.