From automation to collaboration: Sumit Goyal traces the rise of robots and cobots in modern manufacturing.

The manufacturing landscape is being redefined by the seamless integration of robots and collaborative robots (cobots), which have become indispensable to modern production. These sophisticated machines are transforming diverse sectors—from the high-energy chaos of automotive assembly lines to the meticulous precision of electronics workshops—by streamlining processes, enhancing quality, and unlocking new levels of efficiency. As cornerstones of Industry 4.0’s ‘smart factory’ vision, robots and cobots enable interconnected ecosystems where machines, systems, and human ingenuity converge. The adoption of cobots is increasing due to their ability to collaborate with humans, fostering safer and more adaptable workplaces, better suited to thrive in today’s fast-evolving markets.

The rise of robots in manufacturing

Industrial robots have been the backbone of manufacturing for decades, particularly in the automotive industry, where their precision and speed have revolutionised production. These robust machines excel in tasks like welding--to create flawless seams for vehicle chassis, assembly - to position components with pinpoint accuracy, and painting – to ensure uniform coatings for enhanced durability. By automating repetitive, high-volume tasks, robots minimise human error and accelerate production cycles, allowing manufacturers to meet stringent deadlines and quality standards.

Beyond automotive, robots have become vital in metalworking, where they handle complex operations like cutting, grinding, and forming with unmatched consistency. For instance, in steel fabrication, robots carve intricate patterns into raw materials, enabling bespoke designs for construction and machinery. In electronics, they assemble delicate components—such as microchips and circuit boards—with a finesse that human hands struggle to match, ensuring reliability in devices like smartphones and medical equipment. Heavy industries, including aerospace and shipbuilding, are increasingly reliant on robots for large-scale tasks, such as moving massive components or welding aircraft fuselages, as their strength and precision reduce risks and enhance outcomes. By 2023, the global pool of active robots had grown to nearly 4 million units, a testament to their pervasive influence across manufacturing.

Chart 1.1 details global industrial robot installations by the customer industry. In 2023, global installations remained strong, led by the automotive sector (135,461 units) and closely followed by electrical/electronics (125,804 units)

This widespread adoption stems from robots’ ability to operate in controlled environments, often behind safety barriers, where they perform tirelessly around the clock. Advances in sensor technology and programmable logic have made them more adaptable, capable of switching between tasks with minimal downtime. For example, in automotive plants, a single robot can pivot from welding to material handling based on real-time production needs, optimising factory workflows. Their role in driving efficiency has made them indispensable to industries striving to remain competitive in a globalised economy.

Enter cobots: A new era of collaboration

Collaborative robots, or cobots, represent a groundbreaking shift in automation, designed to work safely alongside humans without the need for isolating barriers. Equipped with advanced sensors and force-limiting technology, cobots detect human presence and adjust their movements to prevent collisions, making them ideal for shared workspaces. Unlike their heavier, more rigid counterparts, cobots are lightweight, portable, and intuitive, allowing workers to reposition or reprogram them with ease. This flexibility has made them a game-changer for manufacturers aiming to balance automation with human creativity.

In electronics, cobots are transforming assembly lines by handling repetitive tasks like screw-driving or placing tiny components, freeing workers to focus on quality control and innovation. For example, in smartphone production, cobots align screens with precision, ensuring seamless integration while technicians oversee aesthetic and functional checks. In metalworking, cobots take on hazardous tasks like polishing or deburring, smoothing rough edges on parts while reducing workers’ exposure to dust and noise.

Cobots’ user-friendly interfaces allow workers with minimal technical expertise to program them in hours, not weeks. This democratises automation, enabling SMEs to compete with larger firms. In industries like food processing, cobots are even packaging delicate items like pastries, adjusting their grip to avoid damage, and showcasing their versatility. By fostering human-robot collaboration, cobots are redefining factory floors as dynamic spaces where technology amplifies human potential rather than replacing it.

The smart factory vision

At the core of Industry 4.0 lies the smart factory, a vision of fully integrated production where machines, systems, and data converge to optimise efficiency. Robots and cobots are the cornerstones of this transformation, bridging physical tasks with digital intelligence. Connected via the Industrial Internet of Things (IIoT), robots collect real-time data on performance and wear, enabling predictive maintenance that keeps production lines humming. For instance, in automotive plants, IIoT-equipped robots signal when a welding arm needs servicing, preventing costly breakdowns and ensuring uninterrupted output.

Artificial intelligence (AI) further elevates their impact, allowing robots to analyse data and refine processes autonomously. In electronics, AI-driven robots adjust assembly speeds based on component availability, maintaining seamless workflows despite supply chain fluctuations.

By 2030, the majority of manufacturers plan to increase their investment in automation, encouraged by the need for agility in a volatile global market. Smart factories, powered by robots and cobots, are evolving into ecosystems where data flows freely, enabling real-time decisions that enhance quality and reduce waste. For example, in aerospace, robots track material usage to minimise scrap, aligning with sustainability goals. This interconnected approach is turning factories into responsive hubs that adapt to customer needs and technological advancements with unprecedented speed.

Benefits and challenges

The integration of robots and cobots delivers transformative benefits across manufacturing:

• Productivity: Robots drive rapid output in high-volume settings, while cobots amplify human efficiency in collaborative tasks, streamlining complex workflows.
• Quality: Automation ensures consistency, minimising defects in everything from car frames to circuit boards, elevating product reliability.
• Flexibility: Cobots’ quick reprogramming allows manufacturers to pivot between product lines, supporting customisation and market responsiveness.
• Safety: By handling dangerous tasks like welding or chemical coating, robots and cobots protect workers, creating safer environments.

Yet, challenges persist. The upfront cost of cobots, while decreasing, remains a hurdle for SMEs, particularly in developing regions where budgets are tight. Training workers to operate and maintain these systems demands time and resources, requiring a shift from traditional skill sets to tech-savvy expertise. Concerns about job displacement also loom, as automation reshapes roles on factory floors. However, evidence suggests that robots and cobots create opportunities in fields like system design, programming, and oversight, fostering a workforce that evolves alongside technology. Addressing these challenges requires investment in education and accessible financing models to ensure automation benefits all manufacturers.

The future of manufacturing

The robotics market is on a trajectory for significant expansion by 2030, with cobots at the forefront of this evolution. Advances in AI will endow robots with greater autonomy, enabling them to learn from their environments and optimise tasks like never before. The rollout of 5G networks will supercharge smart factories, providing ultra-fast connectivity that allows robots to coordinate across sprawling facilities in real time, from material transport to final assembly.

Mobile cobots, capable of navigating factory floors autonomously, are set to redefine logistics, ferrying components between stations with precision and reducing reliance on fixed conveyors. Affordable leasing models, often dubbed “robotics-as-a-service,” are emerging to lower barriers for SMEs, allowing them to adopt automation without hefty capital outlays. These models are particularly transformative in regions with growing industrial bases, like Southeast Asia and Latin America.

Chart 1.2 shows annual industrial robot installations in the top 10 markets for 2023. China led globally, followed by Japan, the U.S., and Republic of Korea. Emerging markets like India and Mexico saw rising adoption, reflecting a broader global shift toward automation

Conclusion

Robots and cobots are redefining the essence of manufacturing, forging a path toward smarter, safer, and more adaptable factories. As smart factories take shape, these technologies bridge the gap between automation and human ingenuity, driving innovation across industries. Manufacturers who embrace robots and cobots will lead the charge in a dynamic, technology-driven era, delivering quality and efficiency on a global stage.

Sumit Goyal is Consulting Analyst – Industrial Growth Advisory, at Frost & Sullivan. Sumit is a Mechanical Engineering graduate from Ahmedabad and has completed PGPM from ICFAI Business School with a major in Marketing and minor in Operations. He has a keen interest in Statistics and Data Science, and was earlier a Strategy Consultant at NEC Corporation.

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