Advanced foundry technologies could simplify crafting everything from car engines to jewelry. Experts need next-generation methods to handle the millions of metric tons of copper, aluminum, steel and brass incoming from increased demand. Smart technologies are the answer for transforming foundries into sustainable, productive facilities.
How professionals are implementing smart foundries
Smart foundries are embracing innovations like artificial intelligence (AI), digital twins, the Internet of Things (IoT) and remote monitoring to recover losses. There was a 5% decline in the first quarter of 2024, but it eventually saw a 12% growth year over year. These use cases are motivating corporations to hasten implementation.
The Internet of things and Ssensors
Real-time data application is what sets apart many foundries. The information is critical for monitoring key machinery, such as CNC equipment and furnaces. Failures become preventable, and operations become perpetually optimizable. Predicting disruptions eliminates unnecessary downtime and financial losses.
Equipment monitoring is one boon, but the IoT may also oversee workflows, enabling process discovery. Tools like manufacturing execution systems synthesize data to ensure melting temperatures, curing speeds, and alloy mixtures are as precise as possible to reduce lead times and improve quality control.
Artificial intelligence and machine learning
The data the IoT collates delivers the most value alongside AI tools. Combing through datasets is too labor-intensive, and algorithms automate this task. Foundries see the most advantages when leveraging it for quality control improvements. Reports suggest it makes output more consistent and safe to handle in nonferrous foundry facilities.
Because of resource allocation and productivity enhancements, the teams are able to make more high-quality castings. As a bonus, these optimizations also reduce scrap rates, minimizing waste and refining budgets as a by-product.
AI can also look outside of the foundry for insights. The programs can do market research, using demand forecasting to make supply chain operations efficient. Machine learning will more accurately determine client needs without wasting funds to source and inventory overstock.
Automation and robotics
Smart foundries delegate repetitive tasks to robots to allow employees to engage in higher-level work. This includes making cores and post-casting responsibilities like deburring and finishing. Autonomous mobile robots are programmable to handle a series of assignments on a predetermined route and are infinitely customizable and scalable to alleviate labor burdens, especially in an era of worker shortages.
Robotic process automation is another benefit of smart manufacturing in foundries. Devices are equipped with peripherals like computer vision to identify products with defects or find extra material to remove from surfaces before finishing.
Digital Twins
The sensor-based technologies in the IoT allow companies to create accurate digital representations of the most important equipment. Digital twins visualize these efforts — they show the energy consumption of high-temperature environments and suspected wear and tear and old equipment. Experts can deploy advanced algorithms such as the finite element method on top of these models to determine what materials with certain physical properties are best suited for the job.
Over time, the software will have learned enough to function as a planning tool for upcoming orders. It will know the finest details of every process and machine to the point of recommending how operators should use materials for a specific outcome.
How smart innovations force enterprises to overcome
Foundries face numerous challenges before, during, and after implementing Industry 4.0 and 5.0 innovations. However, smart facilities use these inventions as a way to champion some struggles, too. What hurdles might foundries encounter on their digital transformation journeys?
Skills gaps and workforce culture
Talent shortages and an aging workforce highlight several problems. There is a skills gap with technological processes, and learning these skills requires a cultural shift. Foundry workers are set in their ways, and instituting automation and smart operations could elicit job replacement fears or reluctance from tenured employees. Training is necessary to overcome these problems, but educators must be delicate.
Workers may need to learn how to navigate collaborative management software or advanced isostatic pressing tools. During training sessions for digital and physical tools, educators must contextualize everything workers are learning in the everyday benefits they will experience. For example, hard-to-see porosities in castings are a pain for technicians to notice. Reduce frustrations by teaching them how to operate pressing tools because they consistently remove them for better output.
Integration complexity
Many facilities have legacy equipment. While such devices may already include peripherals like artificial intelligence or Big Data analytics, the IoT may be inoperable on old equipment. The compatibility concerns make transitions more challenging, but they are surmountable:
- Conquer data silos: Consolidate fragmented data sources to reduce compatibility concerns.
- Retrofit machinery: See what legacy equipment can receive upgrades without complete replacements.
- Vendor research: Many operability issues come from having too many vendors, so discover the best ones to have a streamlined ecosystem.
Data management and security
Several agencies are seeking the Cybersecurity Maturity Model Certification to work with Department of Defense contractors. Numerous organizations need trusted foundries to fabricate chips or use processes that support next-generation security, but everything from power tools to client management software are openings for threat actors. Foundries are no exception.
As other entities amplify digital safety efforts, factories must do the same to keep clients. They must hire intelligence like penetration testers or cybersecurity analysts to discover vulnerabilities needing mending.
High investment costs
Capital expenditures include acquiring new tech and the time involved in installation and acclimation. Consider permits, software and other infrastructure upgrades, and accounting teams have a long list of expenses. Smart manufacturing may seem out of reach for smaller foundries, but gradual implementation is possible, even if returns on investment (ROI) are hard to discern.
Foundries can start by cutting energy consumption and using mindsets like lean manufacturing to cut resource use to open budgets, then progressively implement tools. Teams can prioritize equipment installations by what will bring them immediate ROI so funds can divert to the next smart upgrade.
Future foundries
In the next several years, all foundries will embrace smart tools and technologies. The power these resources contain prove why implementation is urgent. It benefits individual companies and their stability and improves the lives of workers. The most competitive and forward-thinking facilities will advertise their commitment to future technologies, establishing the new normal in the sector.
