Cobots can boost productivity rates by up to 85 percent when working with humans
Published on : Tuesday 02-04-2024
Anshul Rathore, Product Architect (Mobile Robotics) at Addverb.
What are the current global trends in the use of robots and cobots in manufacturing industries?
The global manufacturing landscape is experiencing a significant development in automation. While industrial robots have been a foundation of factory production for decades, a new era of collaborative automation is emerging. This paradigm shift is driven by the increasing adoption of collaborative robots, or cobots, which are designed to work seamlessly alongside human workers. The global trend in manufacturing robotics leans towards collaborative, adaptable, and cost-effective solutions that augment the human workforce rather than supplant it entirely. Cobots are at the forefront of this movement, offering expanding capabilities and user-friendliness that make them a valuable asset for manufacturers across the industrial spectrum. Some of the key trends shaping the utilisation of robots and cobots within the contemporary manufacturing environment are:
Surge in Collaborative Robots (Cobots): Traditional industrial robots operate in isolated environments. In contrast, cobots are designed for safe, collaborative work alongside human operators. This expanded functionality allows cobots to tackle a wider range of tasks, particularly those requiring human-like dexterity or involving frequent variation.
Emphasis on Adaptability and Cost-Efficiency: Manufacturers are increasingly prioritising automation solutions that adapt to evolving production demands. Cobots address this need perfectly due to their ease of programmability and rapid redeployment for new tasks. Additionally, cobots are typically more affordable than traditional robots, making them a viable option for smaller and medium-sized enterprises (SMEs) seeking to enhance their automation capabilities.
Human-Robot Teaming: The narrative surrounding industrial robots is shifting from complete workforce replacement to a focus on human-robot collaboration. Cobots can automate repetitive or hazardous tasks, freeing up human workers to engage in higher-value activities that leverage their creativity and problem-solving abilities.
Adoption in Emerging Economies: Previously, robot and cobot utilisation was largely concentrated in developed nations. However, with declining costs and growing recognition of their benefits, manufacturing hubs in Asia and other emerging economies are also experiencing a rise in robot and cobot use.
Convergence with Advanced Technologies: Manufacturing is undergoing an Industry 4.0 revolution, characterised by the integration of advanced technologies like big data analytics and cloud computing. This trend fosters real-time process optimisation, predictive maintenance, and improved decision-making throughout the production cycle, further amplifying the impact of robotics.
In what ways do robots and cobots contribute to increased efficiency and productivity in manufacturing?
In the manufacturing landscape, innovation is vital to stay ahead of the competition. The quest for increased efficiency, improved safety, and enhanced productivity has led to the rise of remarkable technological advancement in robots and cobots. These intelligent machines have transformed manufacturers’ operations, offering a unique blend of automation and human interaction. The growing adoption of robots and cobots in manufacturing is reshaping industries around the globe, revolutionising production lines, and unlocking new possibilities. These technologies play a powerful role in boosting efficiency and productivity within the manufacturing sector. Here's how they achieve this:
Automating Repetitive Tasks: Manufacturing often involves repetitive tasks like welding, painting, and assembly. Robots excel at these tasks, performing them consistently and tirelessly, freeing up human workers for more complex activities that require judgment and creativity.
Enhanced Accuracy and Consistency: Robots are programmed to perform tasks with high precision, minimising human error and ensuring consistent product quality. This reduction in defects translates to less rework and ultimately, higher yields.
Increased Speed and Throughput: Robots can operate at faster speeds than humans, particularly for physically demanding tasks. This translates to a significant increase in production output and throughput within a given timeframe.
Reduced Downtime: Robots don't require breaks and can operate for extended periods. This minimises downtime and keeps production lines running smoothly, leading to increased overall efficiency.
Improved Worker Safety: Robots can take on hazardous tasks like handling heavy materials or working with dangerous chemicals. This reduces the risk of workplace accidents and injuries, creating a safer environment for human workers.
In the case of cobots, they offer some additional benefits:
Flexibility and Adaptability: Cobots are easier to program and redeploy compared to traditional robots. This allows them to adapt to changing production requirements and tackle a wider range of tasks, enhancing overall production flexibility.
Human-Machine Collaboration: Cobots can work alongside human workers, assisting them with tasks or handling specific portions of a larger process. This collaborative approach leverages the strengths of both humans and machines, optimising efficiency and productivity.
By automating repetitive tasks, improving accuracy, and enabling continuous operation, robots and cobots significantly enhance efficiency and productivity in today's manufacturing facilities.
How can manufacturers effectively integrate robots and cobots into existing workflows? Do these replace human labour or create additional opportunities?
According to a recent study by Research Dive, the global collaborative robot market is projected to exceed a staggering USD 8,840.5 million by 2026, with a remarkable compound annual growth rate (CAGR) of 41.2%. This exponential growth signifies the increasing recognition and adoption of cobots in the manufacturing sector as industries seek to unlock their tremendous potential. To ensure effective integration of cobots into existing workflows, manufacturers should follow a systematic approach involving planning, analysis, development, and presentation. This process allows stakeholders to make informed decisions about cobot integration, address worker and business preferences, and consider practical engineering constraints. Key factors for successful cobot integration include understanding work environments for safe operation, making informed decisions based on worker preferences and business outcomes, and addressing organisational leaders' knowledge gaps.
Manufacturers can optimise cobot integration by choosing the right cobot based on task requirements, integrating them seamlessly into existing workflows, and training staff effectively for human-cobot collaboration. Cobots offer benefits such as enhancing productivity, improving workplace safety, and driving cost efficiency in manufacturing processes. Large companies are increasingly adopting cobots due to their user-friendly interface, flexibility, and ability to enhance productivity and quality while reducing downtime.
They can create additional opportunities rather than replacing human labour. They can take over monotonous and dangerous tasks, allowing human workers to focus on more critical processes that provide more value to their company. Cobots can also boost productivity rates by up to 85% when working together with humans, and they can help maintain and create manufacturing jobs by solving issues related to high labour costs and skilled labour shortages. By carefully considering factors like task requirements, workflow integration, and staff training, manufacturers can harness the full potential of cobots to drive significant improvements in productivity, safety, and cost efficiency within their manufacturing processes.
What skills are required for workers to effectively operate and collaborate with robots or cobots?
Cobots can do risky, time-consuming, or repetitive jobs in place of human operators in a safe manner. Not only does this give businesses new chances to boost output and effectiveness. Employees will also have the chance to learn new abilities and information needed to use this technology.
Managing and operating with robots or cobots (collaborative robots), requires a combination of technical expertise, soft skills, and flexibility. The following are some essential skills required for workers to operate and collaborate with robots or cobots:
Technical Skills:
-To operate, configure, and debug robots or cobots, one needs a basic understanding of programming.
-Ability to comprehend the mechanical components of robots or cobots and carry out simple maintenance duties.
-The capacity to interact with and control robots through user interfaces.
Safety Skills:
-Understanding safety guidelines and practices when working with cobots or robots in order to avoid mishaps and harm.
-The capacity to evaluate any dangers related to robot activities and put in place the necessary safety precautions.
Problem-Solving Skills:
-Ability to identify and fix technical problems that may occur when a robot or cobot is operating.
-Capacity to assess circumstances, recognise issues, and reach well-informed conclusions in order to maximise robot performance.
Communication Skills:
-The ability to utilise robots or cobots as a team and be aware of their limitations and capabilities.
-The capacity to effectively communicate instructions, feedback, and problems to fellow employees and robot operators.
Flexibility
-Willingness to adjust to modifications in jobs or work processes when automation and robotics are included into the workplace.
-Being willing to pick up new skills and technology in order to stay up to date with robotics breakthroughs.
Workers that possess these abilities may efficiently operate and interact with robots or cobots, resulting in increased production, safety, and efficiency across a wide range of sectors.
How are manufacturers addressing the need for training and upskilling their workforce in the era of robotic automation?
Global manufacturing is experiencing an increasing productivity dilemma. While firms race to capture retiring workers' expertise before they depart, integrating that knowledge with emerging technology, like robotics, is becoming increasingly difficult due to a growing skills gap. Globally, the World Economic Forum predicts a shortfall of more than 7 million qualified industrial workers by 2030.
Manufacturers are addressing the requirement for training and upskilling their staff in the era of robotic automation using a range of strategies and initiatives:
Training Programs and Workshops: Many manufacturers provide training programs and courses geared primarily toward robotic automation. These classes cover a variety of topics, including robot operation, programming, maintenance, safety measures, and troubleshooting.
Internal Training Centres: Some manufacturers set up internal training centres outfitted with robotic systems, where staff may obtain hands-on instruction and experience operating robots in a controlled setting.
Partnerships with Educational Institutions: Working with technical schools, community colleges, and universities, manufacturers create curricula and certification programs that are specific to the demands of the industry. This guarantees that workers acquire the necessary education and training in robotics and automation.
Vendor Training Programs: Manufacturers frequently work with robotics and automation companies to provide training programs for their personnel. These programs are intended to introduce workers to certain robotic systems and technology utilised in the production process.
Safety Training: As robots enter the workplace, manufacturers prioritise safety training to ensure that employees understand how to operate robots properly and are aware of possible risks related with robotic automation.
Overall, manufacturers understand the significance of investing in employee training and upskilling in order to successfully integrate robotic automation into their operations. Manufacturers want to enable their staff to use robotic technology efficiently and contribute to increased productivity and industry competitiveness by providing comprehensive training programs and chances for continuous learning.
How well do robots and cobots contribute to the flexibility and adaptability of manufacturing processes?
Robots and cobots (collaborative robots) play a crucial role in increasing the flexibility and adaptability of industrial processes. These modern robotic systems may be programmed to do a broad range of activities, from basic repetitive movements to complicated and customised operations, allowing businesses to quickly adapt production processes to changes in product design, requirements, or demand. Furthermore, robots and cobots have rapid changeover capabilities, allowing manufacturers to transition between different activities or production configurations with minimum downtime. Their modular architecture enables scalable and flexible manufacturing capabilities, with the option to add or remove robotic units as needed. Additionally, cobots are particularly intended to function securely alongside human workers, allowing for collaborative operation in a variety of work situations. Advanced robotic systems are outfitted with sensors and real-time feedback mechanisms, allowing adaptive control to alter their actions or settings in reaction to changes in the manufacturing environment. Remote operation and monitoring features provide flexibility by allowing for real-time changes to production parameters from a distance, decreasing the requirement for on-site personnel.
Furthermore, robots and cobots also offer product customisation and personalisation by aiding efficient and accurate production processes, accommodating custom-designed items, and meeting consumer specific demands. By incorporating robots and cobots into manufacturing processes, businesses can adopt agile manufacturing practices that emphasize flexibility, adaptability, and responsiveness to changing market demands, ultimately improving operational efficiency and competitiveness in today's dynamic business landscape.
(The views expressed in interviews are personal, not necessarily of the organisations represented.)
Sources
https://copperdigital.com/blog/industry-4-0-evolution-automation-digital-transformation/
https://www.tm-robot.com/en/advantages-of-cobots/
https://www.universal-robots.com/products/collaborative-robots-cobots-benefits/
https://arxiv.org/html/2401.05587v1
https://praxie.com/cobot-integration-in-manufacturing/
https://praxie.com/cobot-applications-in-manufacturing/
https://www.linkedin.com/pulse/big-companies-small-robots-why-collaborative-attracting
https://www.automation.com/en-us/articles/january-2024/skills-gap-manufacturing-robotics-training
Anshul Rathore in his own words:
Throughout my career, I've had the opportunity to work on a variety of products, ranging from autonomous cars to drones and mobile robots, all with a focus on integrating AI and automation into practical applications. It's been a journey of learning and exploration, driven by a curiosity about how technology can solve complex problems and improve our lives. One of my early achievements, which I'm quite proud of, was receiving a university gold medal for developing a human-computer interface (HCI). This experience was a significant milestone for me, laying the groundwork for my continued efforts in pushing the boundaries of technology and automation.
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