Todays industrial robots work in a wide range of automated industries, from semiconductors and automobiles to plastics processing and metal forging. Pretty much any repetitive operation is a great job for a robot, particularly if its dangerous or difficult for people. Robotic process automation is transforming manufacturing.
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The application of robotics in manufacturing industries is particularly valuable. Manufacturing robots have been used for high-volume processes, but as the technology advances and the cost of industrial robots decline, more options and opportunities are opening for medium- and small-sized operations to leverage robot manufacturing.
At the same time, these robots are helping manufacturers address many of the key challenges they face, including tight labor pools, global market competitiveness and safety. Robotics and manufacturing are becoming increasingly intertwined, with robotics integration enabling more flexible automation.
If youre curious whether robots can enhance your value stream, here are the main pros and cons to consider when it comes to industrial automation and robotics:
Along with other tech such as the industrial internet of things (IIoT), artificial intelligence, data analytics or 3D printing robots industrial robots are able to provide better production quality and more precise and reliable processes. Added benefits also include reduced cycle times and real-time monitoring to improve preventive maintenance practices.
An industrial robot increases speed for manufacturing processes, in part by operating 24/7. Robots dont need breaks or shift changes. The speed and dependability of robots ultimately reduces cycle time and maximizes throughput. Robotic factory automation and manufacturing with robotics enables high efficiency.
Using robots for repetitive tasks means fewer risks of injury for workers, especially when manufacturing has to take place under hostile conditions. In addition, supervisors can oversee the process online or through remote monitoring from a remote location.
The cost of having a person handle many manufacturing operations is often more expensive than a robot. This can also free up workers so their skills and expertise can be used in other business areas, such as engineering, programming and maintenance of the robotics used in manufacturing.
Some argue that robots are taking jobs away from U.S. workers, but thats not necessarily the case. Industrial robots there are typically integrated into a series of operations that require human expertise. For example, you could have a robot welding parts that are handed off to a person to perform a task that requires a humans intuitive "if, then" thinking. The future of robotics in manufacturing involves humans and robots working in factories together.
Robots typically require a large upfront investment. As you research your business case for purchasing, consider all the costs of industrial robots, including installation and configuration. You should also evaluate whether your robot can be easily modified if you need to alter operation in the future. Robotics for manufacturing is a significant investment.
Industrial robots need sophisticated operation, maintenance and programming from controls engineers. While the number of people with these skills are growing, its currently limited. As a result, its important to consider the personnel investment youll need to make to bring in that expertise or retool your existing staff to take on the task of working with robots in industrial automation.
While industrial robots may reduce some manufacturing labor costs, they do come with their own ongoing expenses, such as maintenance. In addition, youll want to consider the costs to keep your robot and any related IIoT-connected devices protected from cyberthreats.
Interested in learning more about the types of industrial robots that would benefit your manufacturing business, from collaborative robots to six-axis robotic arms to autonomous robotics?
If youre ready to explore options for robotics in industry, contact Wipfli to request a complimentary consultation on how robots and manufacturing can work together for your business, from material handling to assembly processing to pick-and-place tasks. Well discuss how automated technology, vision systems, precision control, AC servo motors, cobots and other digital solutions can take your production processes and inventory management to the next level as part of Industry 4.0 and the future of factory robotics.
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Business owners, employees, consumers and the economy all benefit from the plethora of opportunities, with strong industry support provided by the British Automation and Robotic Association (BARA) , part of the Automate UK Group .
As robotics and artificial intelligence have become increasingly sophisticated in recent years, theyre making an ever greater contribution to manufacturing and production.
Recent figures from the International Federation of Robotics show that over one million robots are now used in vehicle manufacturing, and around 3 million are operational in all industries. Other than automotive, key sectors using robotic systems are electronics, metals, machinery, plastics, chemicals and food.
How important are robots for industry? Look no further than the automotive sector, the first to embrace the use of industrial robots, to discover the contribution they can make to manufacturing.
Industrial robots deliver benefits across multiple operations and processes. Robot advantages and capabilities are growing all the time in functions such as:
With improvements in control systems, programming and the deployment of AI and machine learning, robotic automation is set to benefit manufacturers and processing organisations far into the future.
The improvements over manual and mechanical working are fundamental, covering profitability, environmental impact and working conditions for staff.
How do robots vs humans compare? Human error has long been a feature of manufacturing. If human workers are required, a certain number of errors are inevitable and need to be factored into an organisations operating model.
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Robotic systems, by contrast, are by nature both accurate and consistent in their output. Error and subsequent waste are dramatically reduced, while accuracy and consistency are both improved.
The advantages of robotics include an inherent precision and repeatability of operations. This results in a consistently high-quality finish for every product.
Robots eliminate the problems associated with tiredness, distraction and the effects of repetitive and tedious tasks, besides simple human error.
A human worker must take breaks and work set shifts. Robots need no such breaks. As machinery can be programmed to work continuously, production can continue around the clock, boosting productivity proportionately.
The automotive industry, for example, has seen a 50% increase in productivity through robotic process automation (RPA) since .
By using robots, you can achieve a substantial reduction in wastage. You will have more products finished (on the first run) to the standard required by your customers and reduce the amount of breakages and waste produced because of poor quality or inconsistent finishing.
With products being produced to such a high level each time, youll gain greater yields.
Robots in industry can also add flexibility to your production line. Once programmed, they can easily switch between processes, helping you to meet changes in product design or customer demand with a minimum of effort.
Some may have worried that jobs would be lost to robots due to automation. In fact, the opposite is true. By automating monotonous and manual tasks, humans are now being elevated to roles where their skills and abilities can be used and developed.
With the development of new skills comes career progression, better income and more reasons to stay with the current employer.
Whats more, robots in manufacturing have the added benefit of creating new roles that didnt previously exist. Robots will need servicing, software developers, and programmers. Other experts will be required to keep the automated production line running smoothly.
The high precision demanded by todays industrial processes requires the highest levels of skill and training. With highly skilled manual workers becoming harder to find and more expensive to employ, robots can provide an ideal alternative.
Once programmed for your process, robots are ready to begin work with none of the costs associated with recruitment or ongoing training. Robots can also offer greater flexibility, both in terms of work patterns and the ability to handle different production tasks.
With robots, you can improve working conditions for your staff. Theyll no longer have to work in dusty, hot or hazardous environments. In addition, by teaching them how to use robots they can learn valuable programming skills and do work that is more stimulating and challenging.
Working on a production line can be incredibly risky, with health and safety challenges a serious concern for employers and employees alike. One of the benefits of robots in manufacturing is the chance to remove human workers from harms way, elevating them to more meaningful roles within the company.
Robots in factories can take over unpleasant, arduous or health-threatening tasks that may be currently undertaken by manual workers. By using robots, youll decrease the likelihood of accidents caused by contact with machine tools or other potentially hazardous production machinery or processes.
They can also help to eliminate ailments associated with repetitive or intensive processes, such as repetitive strain injuries (RSI) and vibration white finger (VWF).
Robots in the workplace enable you to reduce direct and overhead costs, making a dramatic difference to your competitiveness. Take energy for example. With no requirement for minimum lighting or heating levels, robots offer a great opportunity to cut your energy bills.
Current estimates point to a potential saving of 8% for every 1ºC reduction in heating levels. While savings of up to 20% can be achieved by turning off unnecessary lighting.
Using robots to achieve faster, more efficient production lines can help reduce the capital costs associated with inventory and work in progress. By moving products faster in production, your business can better predict the production rate, ensuring a fast and efficient service is delivered.
To survive in a competitive and fast-changing industrial landscape and to remain profitable and competitive, its necessary to stay abreast of technological developments and master them ahead of your competitors.
History shows us that those who adopt technology earlier are those who survive longer, whilst those who fail to innovate ultimately end up closing their doors. Robotics and automation are serious business, and now is the time to act.
Robots can be mounted in multiple configurations to help you save highly valuable space in manufacturing areas. They can also be programmed to work in confined spaces, so you do not lose valuable floor space.
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