In recent years, the sheet metal processing industry is facing an increasingly severe challenge - the shortage of skilled workers. From the Yangtze River Delta to the Pearl River Delta, many business owners lamented: "It is harder to recruit a skilled bending worker than to find a customer!" According to the "China Manufacturing Talent Development Report", the gap in skilled workers in the sheet metal processing field has exceeded 40%, and the age of practitioners is generally over 40 years old, and there is a serious gap in young labor. Behind this phenomenon is the interweaving of multiple factors such as the decline in the attractiveness of traditional manufacturing to young people, the long technical training cycle, and the soaring labor costs. In this context, automation equipment is regarded as the key to breaking the game. However, can automation really solve the pain points of the industry? 

What practical challenges does its application face? This article will analyze this issue in depth.

1. The triple pressure of cost, efficiency and quality

The shortage of labor has triggered a "domino effect" in the sheet metal processing industry, bringing the triple pressure of cost, efficiency and quality. First, labor costs have soared. The monthly salary of a skilled sheet metal technician has generally exceeded 10,000 yuan. With social security, accommodation and other benefits, small and medium-sized enterprises are burdened with heavy costs. Second, production capacity is limited. The processes such as shearing, bending and welding that rely on manual operation are inefficient and difficult to cope with the surge in orders during the peak season. Some companies are even forced to give up high value-added orders. Finally, there is the risk of quality fluctuations. The accuracy of manual operation depends on experience. Novices are prone to material waste (such as miscutting of stainless steel plates). The rework rate is as high as 15%-20%, further increasing costs and production pressure.

2. "Breakthrough weapon" of automation equipment: from replacement to upgrade

(1) CNC punching machine and laser cutting machine

CNC punching machine and laser cutting machine are the "vanguard" of sheet metal processing automation. They achieve high-precision cutting through digital programming, and the cutting error can be controlled within ±0.05mm, greatly reducing material waste. Taking the laser cutting machine as an example, its processing efficiency is more than 3 times that of traditional manual cutting. It is particularly suitable for the processing of complex shapes and high-value materials such as stainless steel and aluminum alloy.

(2) Automatic bending robots

Automatic bending robots are programmed to preset bending angles and sequences, with errors controlled within ±0.1mm, ensuring the dimensional consistency of each product. One worker can operate multiple devices at the same time, increasing production efficiency by more than 50%. In addition, the robot can automatically adjust the pressure according to the material thickness to avoid deformation or damage to the plate due to improper operation.

(3) Welding robots

Welding robots solve the dependence of special processes such as argon arc welding and spot welding on highly skilled welders. By presetting the welding path and parameters, the robot can stably complete difficult welds, with the yield rate increased to more than 98%. At the same time, the welding robot can also work continuously in high-temperature and high-dust environments, significantly reducing the health risks of manual welding.

3. Breakthrough path: Automation and lean dual-wheel drive

(1) Prioritize high-value processes

In the early stages of automation transformation, companies should give priority to introducing robot equipment in processes with high repetitiveness and high risk (such as stamping, welding, and cutting). For example, in the stamping process, robotic arms can replace manual labor to complete the loading and unloading of plates, avoiding the risk of work-related injuries; in the welding process, welding robots can ensure the consistency and stability of welds and reduce the rework rate.

(2) Cultivate compound talents

Enterprises can establish an internal skill certification system to encourage existing employees to transform to positions such as equipment operation and maintenance, programming and debugging. For example, junior, intermediate and senior technician certifications can be established. Employees who pass the training assessment can get salary increases or job promotion opportunities, which will stimulate employees' enthusiasm for learning new skills.

(3) Embrace digital management

Through the data analysis function of ERP and MES systems, enterprises can identify bottlenecks in production and continuously optimize process flows. Integrate order, inventory, procurement and other data to achieve optimal resource allocation. Real-time monitoring of equipment status, material consumption and production progress provides data support for accurate production scheduling.

The dilemma of labor shortage is essentially a collision between traditional manufacturing models and the needs of the new era. Automated equipment is not to completely replace manual labor, but to redefine production efficiency and value through "human-machine collaboration" - freeing technical workers from repetitive labor and turning to process optimization, equipment management and innovative research and development.

For sheet metal processing companies, automation transformation is no longer an "optional question" but a "must-answer question". Only by actively embracing change can we seize the initiative in the industry reshuffle.