Analysis of Automation in Foundries for Transforming Production Efficiency, Quality Control, and Operational Resilience

The foundry industry, a cornerstone of manufacturing, has undergone significant transformations due to the integration of automation technologies. This survey paper examines the evolution of automation in foundries, exploring its historical development, key adoption drivers, and the ongoing challenges faced by traditional operations. Technological advancements driving this change include the Industrial Internet of Things (IIoT), robotics, artificial intelligence (AI), machine learning (ML), and cyber-physical systems (CPS), such as digital twins. Through case studies, the paper illustrates practical implementations of these technologies, such as IoT-enabled monitoring, robotics in core making and molding, AI-driven defect detection, and CPS integration in smart foundries. The advantages of automation are emphasized, including increased productivity, improved quality control, energy efficiency, sustainability, and enhanced workplace safety. Despite these benefits, the adoption of automation faces significant hurdles, such as high initial investment costs, integration with legacy systems, skill gaps, and cybersecurity concerns. The paper also identifies future trends, including the rise of collaborative robotics (cobots), edge computing, 5G technologies, and the vision for fully autonomous foundries. This comprehensive survey offers valuable insights into the current state of foundry automation, its transformative potential, and future directions for researchers and industry stakeholders seeking to leverage these advancements for operational excellence.