Automation
Precision under pressure. Reliability without compromise.
Metals
Automation that handles the Heat and Load
Automation in the metals manufacturing industry improves efficiency, precision, and safety in tasks like cutting, welding, forming, and material handling. By integrating robotics, PLCs, sensors, and control systems, manufacturers achieve consistent quality, reduce manual labor, and increase production speed. These systems are designed to withstand harsh conditions and manage heavy-duty operations.
Automation also enhances workplace safety by limiting human exposure to high temperatures and repetitive tasks. With real-time monitoring, predictive maintenance, and automated quality tracking, downtime is reduced and traceability is improved. This flexibility helps manufacturers meet rising demand for precision and stay competitive in a demanding market.
What Do We Do?
Primary Processing
Raw material transformation into base metal products (e.g., molten iron, slabs, billets)
- Safety Systems
- Combustion control (air/fuel ratio, pressure, oxygen enrichment)
- Level sensors for molten metal and slag
- Temperature monitoring with pyrometers and thermocouples
- Die automation
- Transfer rails
- Robot transfer
- Uncoilers
- Destack sheet feeders
- Stackers
- Feed lines
- Automatic die change
- Tonnage monitoring
- Die protection
- Hydraulic press control
- Servo press control
- Conveyors, scrap recovery systems
- Marking and vision systems
- Weigh feeders and belt scale automation (coke, ore, lime dosing)
- Process interlocks and sequencing (e.g., tap-to-ladle timing)
Project Spotlight: Mechanical Transfer Press Controls Upgrade for an Automotive OEM
Lineside recently completed a comprehensive controls modernization for a major automotive OEM’s mechanical transfer press—revitalizing critical production equipment with improved safety, diagnostics, and reliability.
Scope of Work
We replaced a legacy Yaskawa PLC with a modern Allen-Bradley GuardLogix platform, upgraded PanelMate HMIs to robust Pro-Face interfaces, and transitioned outdated hardwired safety systems to integrated GuardLogix safety control—bringing the press into compliance with today’s industrial safety standards.
Hardware & Software Highlights
- PLC: Allen-Bradley GuardLogix with integrated safety
- HMI: Pro-Face for durable, operator-friendly interface
- Safety: Upgraded from hardwired safety to GuardLogix safety PLC
Results at a Glance
- Streamlined fault diagnostics and press recovery
- Fully compliant with ISO 13849-1 and ANSI B11.19 safety standards
- Improved system uptime, maintainability, and operator protection
This controls upgrade ensures long-term supportability, reduces downtime, and positions the transfer press for future automation and data integration.
Secondary Processing
Refining and preparing metal for shaping and forming
- Safety Systems
- PLC, HMI
- Drives, servos, motors
- Weld cell integration
- Automatic part positioning
- Weld fixture integration
- Conveyors and transfer systems
- Weld quality monitoring systems
- Vision inspection systems
- Fume extraction
- LASER welder integration
- Marking systems
- Robot integration
- Recipe management systems
- Operator access systems
- Seam tracking systems
- Conveyors
- Marking and Vision Systems
- Communication
- Diagnostics
Project Spotlight: Weld Cell Cycle Time Optimization for an Automotive Tier 1 Supplier
Project Spotlight: Weld Cell Cycle Time Optimization for an Automotive Tier 1 Supplier
Lineside partnered with a leading automotive Tier 1 supplier to reduce weld cell cycle time by optimizing its control architecture—delivering tangible gains in productivity without major hardware changes.
Scope of Work
Our team conducted a detailed analysis of the existing sequence logic, interlocks, and robot handshaking. We then reprogrammed the cell using efficient PLC logic, implemented parallel processing, and fine-tuned the robot-PLC communication timing. Minor HMI enhancements were also made to improve operator interaction and reduce unnecessary delays.
Hardware & Software Highlights
- PLC: Allen-Bradley GuardLogix with optimized sequence control
- HMI: PanelView Plus with cycle analytics and fault tracking
- Robotics: Improved robot coordination and communication
- Diagnostics: Enhanced fault handling and recovery logic
Results at a Glance
- 18% reduction in cycle time
- Improved coordination between robots, PLC, and peripheral devices
- Faster recovery from common faults and interlocks
- No major hardware changes—software-driven performance gains
This project is a strong example of how smart programming and detailed analysis can drive significant efficiency gains—extending equipment life and improving throughput with minimal investment.
Rolling & Finishing Mills
Mechanical deformation and finishing of slabs, billets, or coils into end products
- Safety Systems
- Intrinsically Safe Design
- PLC, HMI, Drives, Servos, Motors
- Robot Integration
- Lifters, Carriers, Conveyors
- Paint Mix Systems
- High Viscosity Material Systems
- Hazardous Location such as Class 1 Div I
- Color Sorting
- Dry Booth
- Feather Dusters
- Communication
- Diagnostics
- Energy use optimization
- Integration to Air Handling Systems
- Paint Body Identification System
Precision Wax Application with 3D Vision-Guided Robots
Our team recently delivered a turnkey robotic wax application system for a global automotive OEM, transforming a manual, ergonomically challenging process into a fully automated, high-precision operation. The project featured six collaborative robots (cobots) equipped with 3D vision and adaptive wax dispensing tools, enabling precise, model-specific cavity coverage without the need for mechanical retooling or safety fencing.
Additional Hardware / Software Highlights
Robotics: Six collaborative robots with integrated safety for human interaction
Vision: Real-time 3D vision sensing for vehicle cavity mapping
Dispensing: Adaptive end-effectors calibrated to vehicle geometry
System Design: Redundancy and predictive diagnostics for >99% uptime
Results at a Glance
30% reduction in cycle time
Uniform wax coverage and improved corrosion protection
Significant reduction in material waste and operator strain
Fast reprogramming for new vehicle models
This fully integrated solution set a new benchmark in precision and safety for wax application, combining intelligent automation with ergonomic design for long-term efficiency and adaptability.
Surface Treatment & Finishing
Post-rolling processes to enhance surface quality and performance
- Safety Systems
- PLC, HMI
- Drives, servos, motors
- Robot integration
- Lifters, carriers, conveyors
- Raku seats
- Lift assists
- Moving platforms
- Nutrunner integration
- AVI/QIS/ALC
- Marking systems
- Sealant and adhesive dispensing
- Torque monitoring and logging
- Riveting & clinching systems
- Conveyors
- Autonomous Mobile Robot (AMR) Integration
- Marking Systems
- Vision/inspection Systems
- Communication
- Diagnostics
Comprehensive Controls and Safety Upgrade for Vehicle Lifters
Our team recently completed a full safety and controls modernization project for an automotive OEM’s vehicle lifter systems. The project involved replacing legacy Allen-Bradley PLC5 controllers with modern GuardLogix platforms and upgrading outdated PanelMate HMIs to user-friendly PanelView Plus interfaces. We also integrated advanced safety features, including light curtains, area scanners, emergency stop buttons, and Safe Torque Off (STO) functionality.
Additional Hardware / Software Highlights
PLC: Allen-Bradley GuardLogix with integrated safety control
HMI: PanelView Plus for improved diagnostics and system visibility
Safety: Light curtains, area scanners, and STO for comprehensive operator protection
Results at a Glance
40% reduction in mean time to repair (MTTR)
Fully compliant with ISO 13849-1 and ANSI/RIA R15.06 safety standards
Enhanced system uptime and simplified maintenance
This turnkey upgrade not only improved safety and reliability but also positioned the lifter systems for future expansion and Industry 4.0 integration.
Material Handling & Logistics
Movement and staging of product between process stages
- Safety Systems
- PLC, HMI
- DCS
- SCADA
- HVAC control
- Air handling units
- Pump control
- Fan control
- Sensing
- BMS integration
- Compressor control
- Leak detection and usage logging
- Hydraulic Press Control
- Automated lighting control
- Power meters and energy analyzers
- Renewable energy integration
- Energy usage optimization
- Automated gates, doors, turnstiles
- Badge and biometric access control systems
- Alarm & event management, data logging and report generation
Project Spotlight: Air Handling System Optimization for an Automotive OEM
Project Spotlight: Air Handling System Optimization for an Automotive OEM
Lineside recently helped an automotive OEM optimize their facility’s air handling units (AHUs) by integrating variable frequency drives (VFDs) and implementing a dynamic control schedule—resulting in major energy savings and better environmental control.
Scope of Work
We retrofitted existing AHUs with Allen-Bradley PowerFlex VFDs, enabling precise fan speed control based on real-time demand. Our team developed a dynamic scheduling algorithm that adjusted airflow based on production schedules, occupancy, and ambient conditions. The control logic was deployed on a central PLC with visibility through the building’s SCADA interface.
Hardware & Software Highlights
- Drives: Allen-Bradley PowerFlex VFDs for fan speed modulation
- PLC: Centralized Allen-Bradley CompactLogix for control and scheduling
- Scheduling: Dynamic runtime schedule based on shifts and facility load
- HMI/SCADA: Real-time monitoring and energy tracking dashboard
Results at a Glance
- 30% reduction in energy consumption on AHU systems
- Improved indoor air quality and climate stability
- Fully integrated with building automation systems for seamless control
- Reduced equipment wear from smoother ramp-up and shutdown cycles
This facilities upgrade proves how smart automation and demand-driven control can lower operating costs and support sustainability goals—without compromising comfort or production needs.
Utilities, Monitoring, and Safety Systems
Infrastructure to support, protect, and optimize the full facility.
- Safety Systems
- PLC, HMI
- DCS
- SCADA
- HVAC control
- Air handling units
- Pump control
- Fan control
- Sensing
- BMS integration
- Compressor control
- Leak detection and usage logging
- Hydraulic Press Control
- Automated lighting control
- Power meters and energy analyzers
- Renewable energy integration
- Energy usage optimization
- Automated gates, doors, turnstiles
- Badge and biometric access control systems
- Alarm & event management, data logging and report generation
Project Spotlight: Air Handling System Optimization for an Automotive OEM
Project Spotlight: Air Handling System Optimization for an Automotive OEM
Lineside recently helped an automotive OEM optimize their facility’s air handling units (AHUs) by integrating variable frequency drives (VFDs) and implementing a dynamic control schedule—resulting in major energy savings and better environmental control.
Scope of Work
We retrofitted existing AHUs with Allen-Bradley PowerFlex VFDs, enabling precise fan speed control based on real-time demand. Our team developed a dynamic scheduling algorithm that adjusted airflow based on production schedules, occupancy, and ambient conditions. The control logic was deployed on a central PLC with visibility through the building’s SCADA interface.
Hardware & Software Highlights
- Drives: Allen-Bradley PowerFlex VFDs for fan speed modulation
- PLC: Centralized Allen-Bradley CompactLogix for control and scheduling
- Scheduling: Dynamic runtime schedule based on shifts and facility load
- HMI/SCADA: Real-time monitoring and energy tracking dashboard
Results at a Glance
- 30% reduction in energy consumption on AHU systems
- Improved indoor air quality and climate stability
- Fully integrated with building automation systems for seamless control
- Reduced equipment wear from smoother ramp-up and shutdown cycles
This facilities upgrade proves how smart automation and demand-driven control can lower operating costs and support sustainability goals—without compromising comfort or production needs.
What Automation Brings to Your Business
How can automation help reduce downtime and maintenance in automotive plants?
Automation reduces downtime in automotive plants through predictive maintenance, real-time monitoring, and early fault detection. By identifying issues before they cause failures, it minimizes unplanned stoppages and extends equipment life.
Automated scheduling and performance insights also improve maintenance efficiency, helping manufacturers maintain high productivity and lower costs.
How does automation impact quality control in vehicle production?
Automation enhances quality control by ensuring consistent, precise processes and reducing human error through real-time detection with vision systems, sensors, and AI tools. Continuous data logging and analysis help identify trends, enabling quick corrective action and ongoing process optimization.
This minimizes waste and rework, ensures compliance with industry standards, and supports high product reliability and customer satisfaction.
What are the safety benefits of automation in automotive manufacturing environments?
Automation improves safety in automotive manufacturing by reducing human exposure to hazardous tasks, environments, and repetitive strain. Robots handle high-risk operations like welding, stamping, and material handling with precision, while built-in safety systems detect anomalies and enforce emergency protocols.
This creates a safer, more controlled work environment, lowering injury rates and allowing employees to focus on supervision and oversight.
How do automated systems support scalability and flexibility in vehicle production?
Automation enables fast adjustments to production volume and vehicle variations, providing the scalability and flexibility needed in modern automotive manufacturing. Technologies like PLCs, robotics, and modular systems allow quick reconfiguration with minimal downtime, helping manufacturers respond to changing demand and shorten lead times.
This adaptability supports lean manufacturing by reducing waste, optimizing resources, and maintaining consistent, efficient output in a competitive environment.