Automation & Smart Manufacturing

Automation & Smart Manufacturing at Sypris Technologies

Sypris Technologies integrates advanced automation and data-driven manufacturing systems to drive process stability, throughput efficiency, and part quality across all production disciplines. Our investment in smart manufacturing technologies enables repeatable execution, reduced cycle times, and real-time performance monitoring at both the equipment and enterprise levels.

We apply automation strategically across forging, machining, welding, heat treating, and assembly operations; not as isolated technologies, but as a fully integrated production ecosystem.

Intelligent Automation Architecture

Our automation infrastructure is designed for flexibility and scalability. From robotic work cells to data-rich PLC networks, we configure systems that support both high-volume production and mixed-model manufacturing environments.

Automation platforms include:

• Robotic Cells: Multi-axis robots for material handling, welding, and machine tending
• CNC Machine Integration: Automated part loading/unloading with vision systems and tool condition monitoring
• Programmable Logic Controllers (PLCs): Custom ladder logic and HMI interfaces for real-time control
• Palletized Transfer Systems: For sequenced flow between machining, inspection, and assembly stages
• Error-Proofing (Poka-Yoke): Sensors, interlocks, and feedback loops to prevent human or process errors

Smart Manufacturing Systems

We have implemented enterprise-wide digital systems to enable data capture, process analytics, and predictive response across the production lifecycle. These tools support decision-making at the operator, engineer, and executive levels.

Digital manufacturing capabilities:

• MES (Manufacturing Execution Systems): Real-time production tracking, work order control, and route enforcement
• SCADA Systems: Supervisory control of process data, alarms, and energy usage
• SPC Integration: Continuous quality monitoring tied to upper/lower control limits and live corrective action triggers
• Predictive Maintenance: Vibration, thermal, and cycle count analysis to prevent unplanned downtime
• Digital Dashboards: Live KPIs for OEE, scrap, downtime, and cycle adherence across departments

Use Case Applications

Automation is deployed where it yields maximum operational impact; enhancing safety, repeatability, and capacity while reducing labor variation and rework.

Integrated automation use cases:

• Robotic welding with seam tracking and adaptive arc parameters
• CNC machining with automated gauging and in-process inspection
• Forging line billet feeding and part ejection systems
• Heat treat batch loading with barcode-driven recipe selection
• Torque control and vision validation in assembly cells

Continuous Improvement Through Automation

Automation is a core enabler of our Lean and Six Sigma initiatives. It supports standard work, error reduction, takt time alignment, and defect prevention; all critical to our culture of continuous improvement.

Methodologies enhanced by automation:

• 5S + Visual Controls: Automated alerts and displays
• Kaizen Events: Focused automation upgrades based on bottleneck analysis
• TPM (Total Productive Maintenance): Autonomous maintenance alerts and diagnostics
• SMED (Single-Minute Exchange of Dies): Automated tooling and part setup transitions

Competitive Advantages

• Cross-Functional Integration: Engineering, maintenance, and operations collaborate to design scalable automation solutions
• Vertical Process Automation: Automation applied from raw material through final inspection
• Data-Driven Decisions: Operational metrics feed back into process optimization and capital planning
• Customer Alignment: Systems configured to support traceability, PPAP requirements, and real-time visibility for OEMs and Tier 1 partners