As discussed in the November issue of Stamping Productivity, sheet metal fabricators are struggling to find skilled machine operators. As a result, many of them are turning to automation as the solution. The question then becomes: what kind?
That earlier story was titled, “Cobots meet stamping.” As the name suggests, it’s chock full of information from Universal Robots on the company’s primary offering – collaborative robots, a.k.a. cobots – as well as some tips on integration and whether to “go it alone” on the installation (spoiler alert: it’s a bad idea). There is also an emphasis on why it’s crucial to perform a safety assessment before turning on that bad boy.
This article offers a complementary though contrasting viewpoint from two well-known names in automation – robot, cobot and machine control manufacturer Fanuc America, together with one of its authorized system integrators and industrial automation expert, Acieta. As stated on its website, Acieta’s team of 300-plus automation experts has designed and implemented more than 10,000 systems across North America, bringing “proven experience and dedicated resources to guide your automation journey.”
So without further ado, here’s what you might call part two of that earlier story. And while some sequels are better left on the cutting room floor, this one is a good read. Enjoy!
Adaptability matters
Troy Sather, district manager at Fanuc America, starts the discussion by noting that today’s sheet metal shops are diversifying, often running stamping presses, press brakes, lasers, welding cells and CNC machines within the same facility. Automation is increasingly essential to staying competitive, which is why manufacturers are looking for automation that can adapt to changing production demands.
“Stamping operations present unique challenges – part variability, die changes and operator safety,” he says.
The goal is to match automation to the realities on the shop floor. For example, Fanuc’s M-20iD/25 and R-2000iC industrial robots are designed for high-speed material handling and press tending. With extended reach and high payload capacity, these models are suited for a wide range of forming applications. One reason the R-2000iC/165F is commonly used in automotive stamping lines is its ability to manage large parts and operate in harsh environments.
Collaborative robots are also entering the conversation. Cobots are designed for tasks that benefit from human interaction or require frequent repositioning. Models like the CRX-10iA and CRX-30iA offer lightweight design and integrated safety features that allow them to operate alongside workers without fencing. This makes them a practical option for smaller shops or applications where flexibility is key.
Ease of deployment is another consideration. A shop can start with a single robot tending a press brake or stamping press and expand into multi-machine automation as production volumes increase. To validate new processes before installing hardware that will boost throughput, simulation software tools can be used.
“Fanuc’s RoboGuide simulation software allows users to model automation scenarios, optimize robot paths and confirm cycle times before implementation,” Sather says. “The teach pendant interface makes it easier for operators to learn and manage robot tasks.”
In stamping environments, robots may be paired with vision systems, force sensors and custom end-of-arm tooling to handle complex part geometries and variable lot sizes. This adaptability is especially important in job shops and non-automotive environments where production needs change frequently.
Overall improvements
Safety remains a top priority. Cobots use power- and force-limiting technology to prevent injuries and equipment damage. Industrial models are equipped with advanced safety features and can be configured to meet regulatory requirements.
“Automation should enhance productivity without introducing new risks,” Sather says.
Fanuc works with partners like Acieta to ensure that each system is tailored to the customer’s specific requirements. “It isn’t just about selling equipment,” he explains. “It’s about helping manufacturers improve consistency, reduce labor challenges and unlock new production capacity.”
Drew Kellogg, regional automation manager for Acieta, is passionate about helping manufacturers realize the full potential of automation; a goal that goes far beyond a simple equipment sale.
While Acieta offers diverse robotic solutions, what Kellogg truly emphasizes is the value of a collaborative partnership. He and the Acieta team bring decades of experience, working closely with customers to design, build and install custom-engineered automation systems perfectly tailored to their specific stamping and forming operations, whether robotic, cobotic or a seamless blend of technologies. For Acieta, success is measured by the long-term results, stronger partnerships and competitive advantage its customers achieve.
Find the start
Many shops recognize the need for automation; the challenge isn’t convincing them to adopt. The real hurdle is figuring out where to begin and whether automation will deliver the ROI they need.
Drawing on extensive experience, including numerous stamping installations and over two decades working with a mid-sized manufacturer in northern Minnesota, Kellogg understands the pressure shops face today. Skilled labor shortages, highly variable part shapes and lot sizes, and razor-thin profit margins all make automation a tempting solution, but also one that requires careful planning.
The key is in helping shop owners identify the most strategic starting points. This ensures they invest confidently with solutions tailored to their specific production needs and financial realities.
“There’s no shortage of standard solutions for lathes, welding centers, press brakes and so on that are relatively inexpensive and easy to implement,” Kellogg says. “In Acieta’s case, we might recommend one of our FastLoad or FastBend systems for those applications. But stamping, especially when it’s low volume, can be much more challenging to automate. For starters, parts often vary dramatically in size and shape, which means the end-of-arm tooling requires frequent adjustments or even replacements.
“On top of that,” he adds, “you need easy access in and out of the press, not just to set up the robot and swap dies, but also to run the machine manually for prototyping or for parts that simply don’t make sense to automate.”
For those who decide to automate, he adds, do your homework first. There’s plenty of learning material available, starting with Acieta’s hands-on training classes and Fanuc’s online training as well as the Robotics Beginner’s Guide from the Association for Advancing Automation (A3). Reach out to other shop owners and production managers who’ve already made the leap. Ask questions and, Kellogg is quick to point out, find a qualified A3-certified integrator to support you and your team on the journey.
Making it work
Once you’ve done all that, the key is to find a family of parts large enough to keep a single press busy.
“That’s how you make it work,” he says. “Find a product group that fills 75 or 80 percent of that machine’s capacity, then work with your partner to develop automation that matches the intended mix of parts. That way, they can understand the challenges you face and what you’re trying to accomplish. It’s the best way to ensure a successful, profitable outcome and to be ready for the next project. Because there will be another. The country’s need for automation will only grow as more manufacturing returns to the United States.”
Sather agrees. “Those who lead with a strategic mindset and embrace scalable, flexible automation will be the ones shaping the future. It isn’t just about solving today’s challenges but also building a resilient, future-proof operation that can adapt and thrive. The steps are clear: assess your current needs, partner with trusted experts and start small then expand confidently. The companies that prioritize innovation today will be the industry leaders of tomorrow.”
As management consultant Peter F. Drucker once said, “The greatest danger in times of turbulence is not the turbulence; it is to act with yesterday’s logic.” Put more simply, now is the time to act and to lead.
