F008: Heavy Manufacturing: Robotics For Extreme Applications

The ARM (Advanced Robotics for Manufacturing) Institute has funded hundreds of robotics and AI projects to strengthen US manufacturing. This session will feature a panel discussion featuring experts who have worked with us on our robotic casting and forging projects. We'll review lessons learned, best practices, results from the projects, and next steps to continue transforming casting and forging operations using robotics and AI. Attendees will walk away from the session with action-oriented next steps and learnings that they can apply in their own operations.

Material handling systems are transitioning from isolated mechanical equipment to fully integrated, intelligent automation platforms. This paper presents state-of-the-art automation solutions designed to enhance safety, throughput, reliability, and operational visibility in advanced material handling environments.

Key technologies include automated cranes, ASRS, transfer cars, AGVs, and conveyor systems coordinated through modern PLC architectures and high-performance industrial networks. The paper highlights closed-loop motion control, anti-sway systems, collision avoidance, No-Fly Zones, and condition-based diagnostics that improve both operational precision and personnel safety.

Integration with WMS, MES, and ERP platforms enables real-time product tracking, equipment utilization monitoring, and optimized material flow. The role of scalable industrial IT infrastructure and edge processing is also discussed as a foundation for future AI-driven capabilities.

The proposed automation framework demonstrates measurable improvements in productivity, asset performance, and risk reduction across complex material handling operations.