American Foundry Society surveys each year show that well over 90% of foundries make annual capital investments in their plants. Traditionally, these investments have focused on replacing worn-down equipment, achieving compliance with government environmental and safety regulations, and automating functions traditionally done manually (especially functions where hiring has become difficult).

AFS has encouraged foundries to automate where it makes sense. The skills shortage we have experienced the last few years is based on demographics and was predicted as far back as the early 1990s by a federal commission chaired by Labor Secretary William Brock. Since the national skills shortage in manufacturing is likely to continue for the foreseeable future, automating such functions is often a sound investment.

Early indications are that an ever-larger number of suppliers at CastExpo 2025, next April 12-15 in Atlanta, will be exhibiting robotics and other forms of automation. This will be a chance to speak to vendors face to face and, in some cases, see equipment operating right on the show floor. If your company is interested in exhibiting at CastExpo, please contact my colleague Deana at dbarrueta@afsinc.org.

Focus on Smart Manufacturing

Increasingly, foundry decision-makers are also taking a close look at the data available in their facility and discussing how to analyze and leverage it. In some cases, they are finding that they already have the right data available to optimize operational efficiency, while in other cases additional data is needed. Sometimes, just evaluating the massive amounts of data available can be a major challenge.

Over the last several years, The American Foundry Society has been assisting foundries by providing access to expert presentations on this topic. In July of this year, the Society’s third Foundry Industry 4.0 Conference in Milwaukee provided two full days of expert speakers, including four foundry representatives explaining how data analysis has played a meaningful role at their metalcasting facilities. AFS will continue to present webinars and other programs to assist foundries in this realm.

Moreover, a number of AFS Corporate Member companies specialize in helping foundries leverage the power of smart manufacturing. Often, the advice is to start small and advance from there. Relatively modest initial investments can sometimes make a world of difference in understanding data and optimizing foundry operations.

One way to find these companies is to visit SupplierMarketplace.net and enter 4.0 into the search box. Another option is to participate in the AFS Industry 4.0 Subcommittee chaired by  Jim Wenson (Sinto), where extensive perspectives are shared and discussed in virtual meetings.

Artificial Intelligence and the Foundry

Increasingly, discussions about Industry 4.0 are including references to artificial intelligence (AI). From marketing to predictive maintenance, there may be meaningful roles for AI in the foundry. The AFS AI Subcommittee, chaired by Zach Meadows (EC&S), is meeting virtually on a monthly basis. The meetings are featuring timely updates on AI developments, discussions with experts, and sharing among subcommittee members on how they are approaching AI. Membership in the subcommittee is free of charge for members of AFS. To join this or any other AFS committee, please contact Kim Perna at kperna@afsinc.org.
Modern Casting will periodically focus on Industry 4.0 and AI, so if you have experiences you would like us to know about, please contact Editor Kim Phelan at kphelan@afsinc.org.