Performance Evaluation of Billet Handling Systems: A Review on Time, Safety, Cost, Rejection Ratio, Precision and Efficiency

This review explores the automation strategies and process improvements in billet handling systems, emphasizing six critical factors: time, safety, cost, rejection ratio–quality, precision, and efficiency. Automated loading mechanisms, conveyor networks, and precision forging lines have been employed to shorten handling cycles and enhance workplace safety in manufacturing operations. High-speed billet cutting machines and hot separation techniques have been utilized to increase productivity while reducing rejection rates, ensuring consistent material integrity. Furthermore, innovations such as multi-layer furnaces and automatic loading networks have been introduced to improve throughput and optimize energy consumption. Precision heating approaches using induction and resistance furnaces contribute to defect minimization and process consistency. The use of PLC and SCADA systems has facilitated real time monitoring, fault prediction, and operator friendly interfaces, thereby enhancing reliability and safety compliance. Cost analyses show that automation lowers operational expenses, maximizes equipment utilization, and improves overall process effectiveness. Nevertheless, challenges persist in integrating smart algorithms, handling variability, and ensuring system interoperability within Industry 4.0 environments. This paper lays the groundwork for systematically comparing existing methods with a PLC based automation framework. The findings aim to guide the development of safer, cost-effective, and high-performance billet handling solutions tailored to modern industrial requirements.