A shift for safety in metal forming

By October 30, 2024 4:59 pm IST

Digital transformation of the metal industry aims to improve product quality and safety. This progression includes AI, IoT, and digital twins. Industry leaders suggest that tailored digital transformations can safely make the processes simple and secure.

There are several reasons why the metals and the entire manufacturing industry are going digital. The most important of these is the wider availability and simplicity of use of the sensors, communications infrastructure, and remote access tools that are part of Industry 4.0 and the Industrial Internet of Things, which propel digital transformation. The technologies are now accessible to industry, and even MSMEs are adapting them. With increasing competition, it has now become a necessity.

Metal coercion has been complicated, and all the new controllers used in metal manufacturing can compile critical manufacturing data. With Industry 4.0, yielding, scrapping, speeding, downtiming, and much more are possible. Replacing manual work re-organises the error margin and allows the operator to explore other aspects.

Digital transformation

Digital technologies have taken centre stage in today’s manufacturing space says Jibak Dasgupta, Director General & CEO of IMTMA. The quest is to enhance productivity, cut production costs, and facilitate faster customisation. 

The scope of digital transformation varies per the business’s needs and potential opportunities. It starts with evaluating and analysing market trends, like understanding the primary goal of transformation, whether the quality or the safety needs a change. Small, standard processes can be quickly transformed, while larger processes like line or batch production or job workers require more complex approaches. The effective implementation of digital transformation is when a basic level of automation and field control methods deliver results. It is not enough to install all ERP, sensors, and digital systems in one day; it is important to determine if the intended results are being achieved. Karthik M, Product Manager, Messer Cutting Systems India Pvt Ltd, shares that digital transformation involves various industries investing in new technologies and infrastructure. However, the investment depends on the process and the desired outcomes. Digital transformation often requires investments in modifying existing infrastructure or missionaries to adapt to new technology.

Avinash Khare, a consultant and corporate trainer in New Manufacturing Technology and Automation, compares digital transformation to the advent of cell phone culture. Technology has transformed our lives, influencing payment methods, purchasing habits, and ticket booking. Avinash believes that if we don’t adapt, the world will do it, making it crucial to remain competitive and adapt to the changing landscape.

He shares, “To future-proof our organisations, we must make strategic decisions based on technology, not just ROI. Companies often avoid capital investment and technical training, which is considered muda (activities or processes that don’t add value to the customer) in productivity presentations. However, CapEx is an investment for future survival. Companies with global aspirations should have global footprints, and it is crucial to catch up with the world’s efforts to avoid being left behind. In the past, people brought weapons like guns and cannons, while we carried swords and spears. This can happen again in the digital world, so we have to guard against this possibility.”

Metal Forming and Stamping

Karthik says it is not one technology we have embraced and pursued for years. He shares, “I have been manufacturing thermal equipment for over a decade. The technology that we were originally employing is quite old. The transition to plasma was also gradual, and the laser is currently utilised for various applications, including thin sheets. Manufacturing and product-based companies believe in innovation and continuous improvement as their core strengths. Digital transformation is one of the continuous improvements in this space, making them sustainable and unique, granting federal control over businesses.

Continuing on the same line of thought, Sushant Hirave, Senior Lead Engineer at General Motors Technical Center India, share how the automobile industry requires a consistent model, known as a Mid-Cycle Model (MCM) or facelift model, which can be a three-year cycle. The architecture remains the same, but the appearance, aesthetics, and performance change. The stamping plant is the highest investment in the industry due to high tool costs. Here, digitisation helps carry forward tools and panels in new models without scrapping tools or materials. This minimises environmental impact and conserves resources by preventing the disposal of old materials. Digital transformations in sheet metal form can modify inner and outer parts, allowing for both advancements.

Safety

Cutting operations form high, sharp edges that can harm operators. The latest software, SafetyCulture, WeldEye, etc., can be used during the engineering phase to modify the sharpness of designs. This approach benefits the operator because it helps avoid e-waste and creates fewer environmental issues.

Avinash vocalises that stamping is a labour-intensive industry that requires manual labour, including grinding and poaching on large castings and dies. With digitalisation, the extent of handwork is expected to decrease, making it easier to perform this type of work. Companies are offering machines and fixtures that allow users to hold dies in comfortable positions, allowing them to polish them while standing ergonomically. This significantly improves manual labour, as it reduces the risk of falls and injuries. Management should know the potential risks associated with hand work, such as prone work on the press side. Safety devices, sensors, and light curtains are already used for safety purposes. The persistent issue was inorganic postures; now, digitalisation is here to solve it. The ergonomic and unsafe nature of grinding a die in a production press is due to its short opening. A separate taller press for comfortable grinding is the solution, but this requires an investment. 

Karthik suggests that every machine needs an emergency stop button in zones prone to risk or injury. Despite the presence of safety protocols and equipment, there are still occasional injuries and near misses. Manufacturers can conduct mock trials or drills within the production group to increase awareness and presence of mind. This can help reduce injuries and near misses in the workplace.

Sushant shares that at General Motors, they created 3D printing tools for operators in an unsafe plant environment and reduced the risk of injury by 100%. GM incorporated 3D printing in the stamping area for safety and efficiency in operations. These tools were designed to fit the operator’s measurements and create a comfortable working environment. After a successful experiment, they developed more fixtures for all unsafe situations and employees.

Indian metal forming industry is accepting the advancements with the increase in the economy and automation of heavy equipment and industrial tasks. A single person or team cannot handle multiple mega-projects, and here, digitalisation can ease with advanced automation, material handling units, safety equipment, and tracking for smooth functioning. However, monitoring and tracking processes are missional and require human intervention. Understanding the workings of these systems will help with the adoption of upcoming Industry 5.0, which includes AI and ML.

Quote

Karthik M, Product Manager, Messer Cutting Systems India Pvt Ltd.

Digital transformation must align with each industry’s unique needs. With automation and gradual integration, we can achieve sustainable improvements and adapt to new technology without overwhelming the process.

Avinash Khare, Consultant & Corporate Trainer, New Manufacturing Technology and Automation.

The 360-degree economy amplifies recycling scrap materials like old cars and refrigerators to minimise environmental harm. By recovering metals from waste, manufacturers take responsibility for their materials throughout their lifecycle, fostering sustainability and reducing the reliance on energy-intensive mining.

Sushant Hirave, Senior Lead Engineer, General Motors Technical Center India.

Tooling safety is important in metal handling, and the latest software can modify design sharpness during engineering to avoid waste and reduce scraping. Digitalisation also address safety concerns and reduce the need for scraping.

Jibak Dasgupta, Director General & CEO of IMTMA

The sheet metal industry is judiciously using digital technologies and robotics as parts of its manufacturing process to enable operator safety and quicker processes in manufacturing. 

Devaraya Manjunath Sheregar, President, TAGMA India

The pandemic highlighted the value of digital solutions, prompting tooling companies to embrace digital technologies increasingly. This shift aims to enhance overall business operations and efficiency, emphasising the importance of technological advancement in the industry.