Risk management involves identifying potential risks and creating a plan of action to minimize the dangers and negative impact those risks could have on employees and the entire manufacturing facility. Many risks in production come from the use of machinery and other equipment. Many machines have moving parts that can cause injury or worse and must be part of the risk management plan. If you want to improve or implement a new program to enhance safety in your automotive plant, continue reading as we discuss risk management tips for automotive manufacturing plants.

Regular Assessments

Assessments are the best way to note what aspects of the current risk management plan are working and understand the risks associated with each piece of machinery. Follow the steps below to perform a risk assessment.

1. Perform a walk-through of the entire facility.
2. Identify the purpose of each piece of equipment and the task for each worker using it.
3. Assess possible risks of the machinery.
4. Create mitigation steps to decrease risk, beginning with the greatest threats.
5. Document everything, including the risks, the plan to make the workplace safer, and when and how you implement the safety steps.

Assessments must happen at least once a year.

Improve Machinery and Techniques

Technology causes everything to advance, including automotive manufacturing machinery. It’s essential to update or replace equipment that is no longer performing efficiently or cannot handle new safety measures. A facility’s machines may have been state-of-the-art during installation; however, several years later, they may no longer be safe or efficient.

Focus on Prevention

Focusing on injury prevention is one of the best risk management tips for automotive manufacturing plants. Preventative measures and the time they take to implement are well worth it. Focus on prevention with the following methods:

• Safety training and review for all employees
• Require the use of PPE where necessary
• Use guarding for machinery

Being proactive with prevention is better for employees, making them feel loyal to the company; better for consumers, as the effort in prevention builds trust and respect; and better for the company.

At A-line Automation, we’ve been providing safety solutions for machinery for over 25 years. We create custom safety guarding fences for unlimited possibilities for your production plant. A-line Automation ensures satisfaction and strives to exceed your expectations. Contact us with any questions about safety guarding fences and other aluminum fabrication.

Many machines are still running in facilities that have been around since before the OSHA (Occupational Safety and Health Administration) set the standards for machine safety. Since those machines had a design without safeguarding in mind, there are two choices: replace them or find a way to add guards. Replacing machinery is expensive, so the better option is adding safeguards when the machine is still efficient and productive. For more information, read on as we discuss how to design guarding for older machines.

What Is Guarding?

Moving parts on machines can cause severe injuries to workers. Some common injuries include crushed hands, burns, blindness, and amputations. Machine or safety guarding is usually in the form of a fence, shield, or barrier that allows a worker to perform their task while staying protected from any moving parts on the machine.

For some systems, guarding must be removable, while other machines work best with permanent guarding.

Assess the Machine

The first step in choosing the right guarding for an older machine is to assess the equipment. Check the following to determine the abilities of the machine and what type of design for guarding might work:

• Is it a single-feature machine or does it perform various tasks?
• Has it been altered in any way?
• What jobs does the operator perform? How exactly do they use the machine? What do they come in contact with?
• What type of maintenance does the older machine require? Have there been many repairs?
• Is the machine dangerous to repair or maintain? What areas does the maintenance crew deal with?
• What dangers and risks are possible during machine loading for setup or production change?

OSHA Requirements

The OSHA sets the standard for machine guarding to protect machine operators and companies using machinery with moving parts. The organization breaks down the requirements that companies must adhere to for guarding into several specific areas. However, the general requirement is that any machine with parts that have the following must use some type of machine guarding to protect operators and employees:

• Rotating parts
• Flying sparks or chips
• Hazards created by point of operation
• Risks created by in-running nip points

Most hazardous areas stem from machines that use the following methods for production and operation:

• Cutting
• Shearing
• Punching
• Bending
• Motion
• Rotation
• Reciprocation
• Transverse motion

OSHA requires older machines that use these motions and techniques to feature guarding for safety. To meet those requirements, a guard must be able to do the following:

• Stay secure enough so no one can easily remove or tamper with it.
• Protect the machine from falling objects.
• Protect the operator and all others from contact with moving or dangerous parts.
• Cause no interference to the machine operator as they perform their tasks.
• Cause no new hazards.
• Interfere with the lubrication of moving parts on the machine.

Designing the Right Safety Guarding

When selecting guarding for an older machine, consider the following questions:

• What type of hazard are you protecting operators from?
• How is the guard made, and with what kind of material?
• Is customization a possibility? For older machines, especially, this is often needed.
• Does the guarding company offer excellent customer service?

The design company will know what type of guarding your machinery needs, even if it’s an older one. One of the most important things to consider when designing guards for older machines is how the guard adheres to the equipment. The machine should be able to accommodate one of the following:

Fixed Guards

Fixed guarding is permanently attached so that no one can remove it. They are typically simple in design and easy to install.

Interlocked Guards

The design of an interlocked guard uses a tripping mechanism, which causes the machine to cease operation as soon as the guard moves or is no longer there.

Adjustable Guards

Adjustable guards are easy to adjust in size when there is a need to accommodate varying lengths of materials and stock.

Self-Adjusting Guards

Self-adjusting guards adjust on their own when sensing the need of varying sizes of stock that must go through.

The type of safety guard your machine needs will depend upon what purpose it serves, and in some cases, due to an older design, you may be limited on what kind of guard suits the machine.

What if the Machine Manufacturer Doesn’t Make Guards?

With an older machine, it’s likely that the manufacturer no longer exists or doesn’t offer machine guarding that suits your machine, since requirements have changed. In that case and in many other cases, custom-designed guarding is best. There are many benefits to custom-designed guarding, and some of them are as follows:

• They can fit difficult or unique machines.
• You can install them on feeding mechanisms.
• You can install them on individual dies.
• Working with a designer, you’ll have greater knowledge of how the design operates.

You can’t go wrong with a custom design to ensure that the guarding fits properly, suits the older machine, and thoroughly protects everyone from dangerous equipment areas.

Common Materials for Guarding

The three most common materials for machine guarding are wood, plastic, and metal, with metal being the most common and useful. However, with an older machine, you may have to choose what suits it best. Some older machines may need help to handle a specific material.

Plastic is common when the guarded area must be visible to operate the machine properly. Wood is usually only seen on woodworking machinery or when there is the use of chemical vapors that don’t interact well with metal. Otherwise, since wood is flammable, it’s sometimes not a safe choice. On the flip side, metal is highly durable and often used in all types of machine guarding.

A-line Automation has been in the industry for over 25 years and understands the importance of machine guarding for older machines and its impact on the manufacturing process. We design custom aluminum profiles for use in high-quality, durable guarding systems and more. If you need clarification on the guarding requirements or needs of your machinery, contact us, and we can create the design for you.

T-slot aluminum extrusions are a common choice for guard systems and other safety enclosures; however, they are also the perfect choice for custom designs and any application requiring versatility and strength. Each extrusion has a t-slot, making connections fast and simple. This article will uncover four great reasons to build with t-slot aluminum for your next application.

Cost Savings

Most projects have a budget, and choosing aluminum extrusions helps keep that budget where it needs to be. Aluminum is a cost savings for two reasons: easy assembly and reusable parts. Let's look at each.

Easy Assembly

When compared to applications that require welding, it's easy to assemble t-slots using nuts, bolts, and other fasteners.

Reusable Parts

The reusable parts of t-slot aluminum allow you to move elements around as well as replace and add additional pieces as needed. This benefit saves both time and expenses when considering labor and the cost of new materials.

Flexibility

Since t-slot aluminum is easy to take apart and put together, it allows for great flexibility. Do you need to move a workstation or guard system from one area to another? You can accomplish that by disassembling and reassembling the systems. This flexibility allows the framing systems to be used in other sites if necessary.

Durability

Since it is strong and durable, t-slot aluminum is the material designers choose for handling heavy-load applications in frames, cutting tables, bases, and more. Aluminum can bear significant weight and pressure.

Lightweight

Although it can handle heavy loads, aluminum is surprisingly lightweight. It's lighter weight makes it incredibly easy to maneuver, assemble, and move as necessary.

The next time you need to complete a project and aluminum is one of the choices for the application, remember the four reasons to build with t-slot aluminum. You'll save time and money and be satisfied with the results.

At A-line Automation, we believe in the durability and flexibility of aluminum extrusions. Our aluminum framing systems are versatile, with endless possibilities. Contact us with your vision or design, and let's get your next project complete.

The Occupational Safety and Health Administration (OSHA) develops the standards for safety guards on machinery to ensure that all workers and employees have the protection they need while on the job. These standards are in place not only to protect employees, but to protect management as well. A company is liable when injuries occur, so using safety measures from the start is essential. To help ensure workplace safety, discover how to choose the right safety guard for your machine and learn more about why it matters.

What Is a Safety Guard?

A safety guard is a mechanism, usually a shield or other device, that surrounds dangerous areas on machinery for the control of flying sparks and other debris. It also serves to keep body parts from accidentally encountering hazardous areas. Hazardous components of machinery include the following:

• Rotating parts

• Reciprocating arms

• Moving belts

• Cutting teeth

• Shearing or impacting

• Punching

• Transversing

The three most common areas of machinery where injuries occur are at the point of operation, through power transmission spots, such as at pulleys and belts, or near any other moving parts.

The Requirements for Safety Guards

Since OSHA sets the standards, there are specific requirements for safety guards that businesses must follow. Let’s look at each standard in more detail.

No Interference

Safety guards are put in place to protect workers; however, if the guard interferes with an employee doing their job, then it is of no use. A worker must perform their role comfortably and swiftly without the safety guard getting in the way.

Secure and Durable

If someone can easily remove the safety guard, then it doesn’t meet OSHA standards. In addition to being secure, the guard must be strong and durable to offer proper protection.

No Contact

The purpose of a safety guard is to help prevent injury due to coming into contact with moving parts on the machinery. A proper safety guard does not allow access to those parts.

Protection From Falling Objects

Falling objects are a risk in some areas of machinery. This means that safety guards must protect workers from these dangers.

No New Hazards

If a safety guard adds more risk to the area, then it’s not a good choice. Ensure that you choose guards with smooth edges and surfaces so the guards themselves don’t cause injury.

Allow for Maintenance

At times, the area that the safety guard is protecting will need maintenance or lubrication. Choose guard designs that allow workers to get around the devices when necessary so they can perform maintenance tasks.

The Different Types of Safety Guards

Although there are several guard styles to choose from for different machines and needs, there are four basic approaches to those styles: fixed, interlocked, adjustable, and self-adjusting.

Fixed Safety Guards

Fixed safety guards are a simple solution for certain types of machinery. This safety guard is adhered to the machine and stays in place after installation, and it does not allow for adjustment. These guards offer little flexibility and work well when there is no need for regular changes. Here are some other pros of fixed safety guards:

• They are suitable for many applications.

• They offer maximum protection.

• They require little to no maintenance.

• They are great for high-production facilities.

There are also a few cons to a fixed safety guard:

• They can interrupt visibility.

• They may limit operations.

• They are difficult to remove for maintenance.

Interlocked Safety Guards

Interlocked safety guards are removable, and one of the biggest benefits of this guard type is that the machine shuts off as soon as removal happens. Here are a few pros and a con of the interlocked safety guard:

• They provide maximum protection.

• Workers can easily access the guarded area when they need to by simply removing the guard—this is especially helpful when there is a jam or broken part.

• The machine immediately stops during safety guard removal.

• It disengages easily because the interlocked safety guard is made for removal.

Adjustable Safety Guards

As some of the most flexible safety guards, adjustable guards make it easy to accommodate various machines. There are a couple of benefits to this type of safety guard:

• They are useful for many different applications.

• As machine size needs change, the adjustable guard can change with it.

Still, the adjustable safety guards have a few downsides, including the following:

• They interfere with visibility if the adjustments are too large.

• They need frequent maintenance.

• It’s harder to protect the dangerous spots if adjustments are not correct.

• The operator may adjust it for convenience and risk injury.

Self-Adjusting Safety Guards

Self-adjusting safety guards are similar to adjustable since the sizes of these guards can also be changed; however, they make things a little easier as they can modify themselves as needed. As stock enters the barrier of the self-adjusting safety guard, the opening will expand accordingly. Let’s look at another pro and a few cons of self-adjusting safety guards:

• They are readily available without the need for custom creation.

• They offer limited protection.

• They sometimes interfere with visibility.

• Some need a lot of adjusting and maintenance.

It’s best to seek the advice of a safety guard specialist or designer before choosing the right safety guard for your facility’s machines.

Machine Safety Guard Maintenance

As you decide on safety guards for your equipment, be sure to keep maintenance in mind. Proper care of your safety guards is imperative to keep them working properly so no one becomes injured. Regular maintenance includes cleaning and routine inspections to make sure everything is as it should be. If there are ever any cracks, tears, holes, or other issues with a safety guard, replacement is necessary as the guard might malfunction if imperfections are present.

When considering the right machine safety guards for your facility, remember to factor in maintenance, the different types of safety guards available, and OSHA requirements. Safety guards for your machines aren’t optional; they’re a necessity for protecting the operators of those machines.

At A-line Automation, we offer custom machine guarding so you don’t have to guess which machine safety guard type or size you need. We can design and create specific guards for your facility and operations. With our extensive line of aluminum t-slot framing and accessories, unlimited configurations are possible. If you have any questions or need help selecting the right safety guards for your machines, contact our friendly team and we’ll make sure your facility’s machines are safe for your operators.

The possibilities for the use of aluminum extrusions are endless. You’ll see aluminum metal fabrication applications in structural frames, the auto industry, assembly lines, test tables, engine blocks, and more. Still, even though aluminum extrusions are commonplace, sometimes there is a need for one with a unique design or measurement. In that case, custom production is necessary. With customs comes a higher price since the design and manufacturing are specialized and unique. If your industry has this type of need, read on to see the five factors that impact the cost of custom aluminum extrusions.

Custom Dies

For the fabrication of custom aluminum extrusions, the first step in the process is a custom die for the product. These dies are tailor-made specifically for an order. It’s possible that after production, the die won’t be used again; therefore, the manufacturer must make up for that loss by adding it to the cost of the custom extrusion.

The Cost of Aluminum

The cost of aluminum often fluctuates, and it is now more expensive than ever, around $1,500 to $3,500/metric ton. For extruders, it’s best to buy in bulk and receive a discount. However, for some custom designs, what’s in stock doesn’t always work, and a custom order of aluminum is the only answer. In that case, the manufacturer must, of course, pass that cost on to the customer.

The Cost of Manufacturing Labor

One of the biggest factors that impact the cost of custom aluminum extrusions is labor and manufacturing. Each step requires a knowledgeable and trained worker to complete it. Here’s a list of processes that require the role of an extrusion specialist when there is an order for custom aluminum extrusions:

• A team to design the die

• A team to manufacture the die

• The ordering of aluminum

• Creating the extrusion

Several people are paid to take care of each step to bring the fabrication to production. Another area that has an impact on manufacturing and labor costs is where production takes place. Keep in mind, aluminum extrusions made in the US don’t incur the same shipping costs as an order from overseas.

Surface Finishing

Surface finishes come into play to improve the look of an extrusion or make it more durable. On average, they vary from about $1,200 to $1,400/metric ton. Some finishes are less expensive and some may be more. Aluminum naturally has a smooth finish after extrusion, but sometimes there’s a need for a different surface. There are two popular options, and they include the following:

• Sandblasting for a rougher surface

• Powder coatings for a durable, hard finish, or for color

Secondary Options

Just as a surface finish isn’t a requirement for a custom design, neither are secondary options. Still, depending on the use, a custom aluminum extrusion sometimes calls for unique elements that aren’t reached with extrusion alone. Let’s look at a few possible secondary options:

• Bending extrusions to avoid straight lines

• Machining to create holes and shapes

• Temper treatments for added durability, hardness, or formability

At A-Line Automation, we are committed to bringing the industry the highest-quality materials, including Bosch aluminum extrusions, which are suitable for many applications. Our list of impressive customers with whom we’ve built relationships speaks for itself. Contact us with any custom design needs, and we’ll bring your aluminum extrusion vision to life.

Builders can choose from many materials like metals for structures and frames. However, not all metals are the same. Some are strong yet stiff, while others are pliable but not strong enough to handle the situation. Ductile metal is necessary for many jobs, and the result is a strong and flexible structure or frame. Follow along as we discuss ductility and its importance for aluminum.

Defining Ductility

When a metal is ductile, it’s flexible and can change physical form without breaking. Imagine a bent metal frame, but the bend doesn’t cause it to break. That metal has ductility and easily stretches and bends.

Many metals are ductile at different levels. Here’s a list of metals that are considered highly ductile:

• Gold
• Platinum
• Silver
• Aluminum

Some metals come in both ductile and non-ductile forms, such as iron. Malleable iron is flexible, while cast iron is brittle but strong.

What Makes Aluminum Ductile?

Aluminum’s low melting point and low density make it ductile, so it can take on any shape and bend easily while remaining strong. Its formability makes it excellent for many structures and frames, especially when the structure must support some movement.

When To Choose Aluminum

Understanding the ductility of aluminum is important, and it’s essential to note that it’s corrosion-resistant and handles thermal conductivity better than steel. Aluminum is the best choice for the following applications:

• Window frames
• Door frames
• Gutters and railings
• Car engines
• Piping
• Storage tanks
• Aircraft components and support structures
• Safety guarding fence
• Assembly lines

As you can see, aluminum is helpful in many situations and remains important for constructing frames of all sizes and shapes.

At A-Line Automation, we are proud to offer the highest quality aluminum structural framing and the essential aluminum pieces you need to expand or replace your current components. With aluminum extrusion fabrication, we bring your design and vision to life. Contact us today, and together, we’ll get your framing system up and running.

An assembly line in mass production processes helps the workflow run as smoothly and efficiently as possible. They usually consist of several workstations, with each station having a job to fulfill. If one workstation is disorganized or not working, the rest of the line might back up and not complete its tasks. Follow along as we discuss how to organize your assembly line workstations for an effective production line.

Production Line Balancing

When considering assembly line production, the first thing to discuss is production line balancing, which refers to the number of workers, machines, and stations needed. When these numbers are correct and well-planned, it brings balance to the line, and the workflow is optimal. When the balance is off, so is the assembly line. Let’s look at some steps to follow when trying to achieve assembly line balancing.

1. Break the production process into segments. It helps to get these segments into a diagram depicting the order in which they happen.
2. Determine the time needed for each process or workstation. You can do this accurately by dividing the available time by the desired output. The answer is your cycle time, which should give you a clearer idea of the time needed for production.
3. Figure out how many workstations you need. The best way to do this is to know the sum of the task times and divide that by how long it should take to complete the tasks. The sum of that is how many workstations you need for the assembly line.
4. Evenly space workstation times. After deciding on the number of workstations, you must estimate how long each task takes at its station. If you have one area that takes double the time of the workstations before and after it, you create a bottleneck in the system. Space out workstations and plan them in a way that the timing works out efficiently. Try to get process times as equal as possible. This might mean breaking one long process into two.
5. Give it a test run. Even after careful calculations, things can be off. The only way to see if the planned workstations are going to run well is to test them. If the system needs changing, do so accordingly and test again.

Organize Each Station

Organization is key for just about anything to run smoothly. Once the workflow and stations run efficiently, you must make sure everything stays organized. Here are some tips for organized workstations:

1. Cutting back on space is not a wise decision. When designing, allow for plenty of room at each workstation. Each task requires the proper amount of space so that workers can complete tasks on time and correctly. The person running that station needs room to maneuver and stay organized.
2. All materials needed must always be available on the workstation. Each item, no matter how large or small, plays a significant role. From machinery to the tiniest screw, keep materials available, clean, and well-maintained.
3. Use drawers, cabinets, and containers for parts and pieces. It helps to place labels wherever possible for quicker assembly.

Keep these thoughts in mind during the assembly line design and production phase. It’s best to plan out every detail rather than to have to go back and redesign.

Keep It Safe

In every assembly line, there is a safety protocol to follow to prevent injuries. Make sure workers understand the safety procedures in the production facility. Keep signs up around workstations as reminders and regularly schedule training refreshers.

Adhere to Schedules

In the production process, there are often several workstations and different areas in the facility. Each area and station work together to create products. When schedules don’t flow properly, every workstation suffers, and production slows.

The only way to avoid this is to adhere to strict schedules. A workstation can’t shut down if things are to run smoothly. You must time breaks, order of procedure, and maintenance times correctly.

The Benefits of the Assembly Line

The creation of assembly lines is for the purpose of mass production. People have used them for hundreds of years, and they’re common in manufacturing. Let’s look at several of the benefits of using an assembly line with workstations.

Increased Production

There’s no getting around it—you can’t produce as quickly without an assembly line. Assembly lines allow for multiple people and workstations to perform one specific task repeatedly rather than a smaller number of workers and stations trying to do it all. This allows workers to finish their tasks quicker, ultimately producing more products.

Lower Cost Per Unit

Although it’s an investment to install an assembly line, the result is an improved profit margin. Labor costs are lower when you have training in place for everyone to perform one particular task rather than one person performing every task. This creates a lower cost per unit during production.

Product Uniformity

When designed correctly, each workstation in the assembly line produces the same product over and over, allowing greater odds that the parts and units all look and feel the same. The likelihood of differences decreases.

Easy To Upgrade

When done correctly, assembly lines and workstations are easy to upgrade when necessary. Choose a company to design your assembly line and workstations that is infamous for its ability to make changes and additions down the road. If the line is inflexible, you’ll find that cost is a hindrance, as you’ll have to start from scratch each time.

When organizing assembly line workstations, keep in mind line balancing, the organization of each separate workstation, safety procedures, and schedules. During the design process for the assembly line, it’s important to test-run it until it’s right.

At A-Line Automation, we provide t-slot aluminum framing solutions and assembly automation components for flexible and durable assembly line options for your warehouse workstations. We understand the importance of an effective assembly line and the need to meet height, positioning, and lighting requirements. Contact us, and let’s discuss your vision for your workstation and create a productive assembly line.