Automation of a Forging Line

Customer's Goal
As part of an ongoing Continuous Improvement Program, the customer wanted to automate an existing manual bar forging line using an existing press and furnace. A fully automated material handling system was also a requirement to address ongoing ergonomic issues and to eliminate injury related days lost with their associated costs and labor premiums.

M.P.T. Solution:
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Automation of a stabilizer bar forging line solution philosophy:
The sheared raw steel bars need to have 6" of end heated prior to forging the eye geometry. Once heated to a preset temperature that has been verified; the first end is forged and trimmed in a 3 station tool. This partially completed bar is now rotated 180 degrees and recirculated through the furnace for the other end to be heated. Prior to forging the second eye, the already formed end is captured and oriented for eye to eye clock rotation and overall length control. The second eye geometry is now forged and trimmed. The completely forged Stabilizer Bar is then loaded onto a pallet for transport to next operation.
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x	Sequence
Automated tote unloaderx	1) Unload raw, sheared bars from tote 2) Load each bar into furnace through escapement 3) Unload bar from furnace when up to temp 4) Orient bar for correct length 5) Load Press. Forge and trim first eye end. 5) Unload Press. Direct bar for recirculation. 6) Rotate semi-complete bar 180 degrees 7) Interleave load semi-complete bar into furnace 8) Unload bar from furnace when up to temp 9) Orient bar for eye to eye clock rotation and correct length 10) Load press. Forge and trim second eye end 11) Unload press. 12) Check bar - if both sides forged correctly, load into tote, if not load into reject bin.

Results
Improved productivity Lower unit cost ~ 23,000 man hours/year labor savings Reduced injury claims

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