Marvel Manufacturing Champions Automation for a Leaner, More Productive Future

Marshall Taylor, a seasoned machinist with over 20 years of experience and the owner of Marvel Manufacturing, is a strong proponent of integrating automation and technology into manufacturing processes. Despite being in business for just three years, his company is already implementing progressive automation strategies, including lights-out operations on their turning centers, enabling machines to run unattended overnight.

Marshall advocates for new automation technologies because he believes they can drive higher production while reducing the need for repetitive, dull, and dangerous jobs. “Contrary to what many in the labor force believe—that automation will eliminate jobs—it actually benefits workers in significant ways,” he explained. By eliminating tedious tasks, job roles evolve from machine operators to automation integrators, robot programmers, and maintenance specialists—skilled positions that offer greater career opportunities and higher wages.

From a business standpoint, Marshall also acknowledges the ongoing labor shortage in manufacturing. He emphasizes, “Rather than paying 10 people entry-level wages to operate machines, paying five people a competitive wage to oversee automated processes results in a more cost-effective and productive solution."

Moving Toward Automation: The Role of Process Organization

While automation has long been a staple in industries like automotive manufacturing, Marshall believes it’s still a huge leap for many small manufacturers. So, where should they start?

Marshall’s advice is clear: focus on process organization. To move toward automation, manufacturers must first ask, “How can I find gains before I automate?” He stresses the importance of standardizing production before adding automation. The key to success is ensuring the manufacturing processes are reliable enough to run unattended. “If the machining process isn’t stable enough to operate without human supervision, it’s not ready for a robot to take over,” he cautioned.

However, not all processes are immediately suited for automation. Taylor advises manufacturers to start with the "low-hanging fruit"—the processes that are easiest to automate. Instead of a one-size-fits-all approach, he recommends identifying an automation solution tailored to the most common tasks performed on a specific machine. This is especially important for job shops that deal with a variety of parts and setups. Manufacturers should ask themselves, “If I’m going to invest in a robot, which family of parts is most suited for it?”

The Costs and Benefits of Automation

For smaller manufacturers like Marvel Manufacturing, Marshall sees collaborative robots (cobots) as a perfect fit for automating processes. Unlike traditional industrial robots, cobots are not confined to caged areas. They are equipped with safety features like lasers and infrared light curtains that detect any interference and force sensors that immediately stop the machine if it comes into contact with an object.

While cobots may appear slower than human operators, they excel in consistent, repetitive tasks, significantly improving output over time. Cobots don’t take breaks, they don’t get tired, and they can run 24/7, unlike human workers.

For small manufacturers, the cost of automating a CNC mill, for example, can range from $60,000 to $200,000 for a machine-tending cobot or automated pallet pool. This cost can increase with additional accessories and tooling. However, when you consider the cost of employing machine operators over the lifespan of the equipment, automation becomes a cost-effective solution. Moreover, the more the robot is used, the lower the operating costs become.

The Role of Software and Human Decision-Making

Automation isn't limited to the shop floor. Marshall emphasizes that software solutions—like ERP systems and quoting software—can also be automated, creating opportunities for increased efficiency across various processes. “There’s software for just about every task you do on paper,” he said. Even final inspections and quality control can be automated to ensure better consistency and product quality.

However, Marshall warns that manufacturers must carefully weigh the costs versus the benefits when deciding to invest in automation. “As with any investment, you need to evaluate the ROI and compare it against potential missed opportunities if you choose to take it on as an expense.”

Despite his enthusiasm for automation, Marshall stresses the ongoing need for skilled human labor. “You can’t replace humans when it comes to decision-making,” he pointed out. While he views artificial intelligence (AI) as a powerful tool for providing accurate and usable information from a specific set of data, he believes human interaction will remain essential when situations fall outside defined parameters.

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