Cobots for Manufacturing
Published on : Tuesday 06-06-2023
Collaborative robots offer a cost-effective, adaptable and safe automation option, says Darshana Thakkar.
With growing global competition, manufacturing companies are under pressure to reduce cost and sustain their business with profitability. Countries like China have captured the global market in almost all the industry sectors with their lowest prices. Despite having huge potential, India cannot compete with Chinese products worldwide due to higher product costs.
For manufacturing companies in India, significant cost challenges lie in higher labour, electricity, and raw materials costs. In recent years, the fast growth of services and other commercial sectors has created a shortage of labour for manufacturing companies. With quick upgradation of technologies, many large corporates of India have already contributed dramatically by adopting the latest technologies. They are at par in using IIoT and Robotics in their manufacturing plants with the developed countries.
In India the MSME sector contributes 30% of GDP and 45% exports in manufacturing. The MSME industry has thus made a considerable contribution to nation-building. Still, as a whole, the production volume is distributed in almost six crore small units, and their individual volumes and financial resources are insufficient to afford robotics in their plants.
Limitations and roadblocks for MSMEs in adopting robotics
1. MSME companies are facing tremendous liquidity crunch due to many reasons. Delayed customer payment, lower margins due to increased labour, and other overhead costs are the main factors apart from the higher initial cost of the robots.
2. Industrial robots are made to perform in high-volume manufacturing processes with low variations. That makes it difficult for small companies to afford the initial and programming cost.
3. It is challenging to reprogram and redeploy new cell settings and part configurations.
4. Industrial robots lift and handle heavy and oversized parts, which can sometimes be hard to reach; they require larger space and fencing for human protection working on the shop floor.
5. Automation experts and programming engineers are required to use robots. For different processes and parts, programming is needed every time. MSME organisations can't afford the cost of highly skilled professionals to deal with small production volumes.
6. In countries like India, employment is still the biggest challenge. Robots replace manual labour. That is increasing overall unemployment. That creates insecurity among the workers with the entry of robots into the company.
Addressing MSME concerns
Dear MSME Business Owners, with my years of experience and investment in dealing with the MSME sector, I understand the areas of concern very well. I am sharing some insights that will be very effective and helpful in the automation and technology upgradation of your plant.
As we all know, MSME owners are closely and emotionally connected with all the employees and are worried about their job if automation is done in the factory. We, the people of India, think twice before firing an employee unless it is a severe matter. So we prefer collaboration instead of competition.
Cobots or co-robots are robots designed and conceived to interact physically with humans in a workspace; the term ‘cobot’ derives from collaborative robots. The cobot works alongside humans and eases the workload, increasing productivity, quality and accuracy.
The origin of the cobot
The first cobot was invented in 1996 by J Edward Colgate and Michael Peshkin. They call the cobot 'a device and method for direct physical interaction between a person and a computer-controlled manipulator'.
Why cobots are proving an effective solution for MSMEs?
1. Easy Programming: Cobots are far more straightforward than traditional industrial robots. Free your employees from routine work and let them become robot operators with more time for the most critical tasks. With intuitive 3D visualisation, you move the robot arm to desired waypoints or touch the arrow keys on the easy-to-use touchscreen tablet.
2. Fast Setup: Robot manufacturers have revolutionised the cobot setup, significantly reducing deployment time. Many standard cobot processes can be programmed after free online essential training. Instructor-led online or in-class modules are available for more advanced tasks. Expert advice is available from distributors, certified training partners, and systems integrators.
3. Flexible Automation: Traditional robots can only do one thing. At the same time, cobots are lightweight, space-saving, and easy to redeploy to multiple applications without changing production layouts. Moving the cobot to a new process is fast and easy, giving the agility to automate even small batch runs and frequent line change-overs.
4. Collaborative and Safe: Give cobots dirty, dangerous, and dull jobs to reduce repetitive strain and accidental injuries to humans. The safety system in cobots is very high and reliable.
Choosing the appropriate cobot
Collaborative robots are becoming increasingly crucial for the MSME sector, and the demand for automation is growing significantly in post-Covid era.
Each cobot has its unique features and specifications. Anyone who wants to start a cobot automation project must look closely at the requirements for successful integration. Range, load capacity, accuracy, speed and the number of axes are necessary specifications to look at beforehand. The appropriate selection based on the respective application and job specification is essential. I am sharing herewith key details of top cobots in the industry.
1. Universal Robots
Universal Robots is the world's largest cobot manufacturer, with almost half the market share. They released two different series with a total of 7 different cobots. The CB3 series comprises the UR3, UR5, and UR10 models; and the E-series with the UR3e, UR5e, UR10e, and UR16e.
All robots have 6 degrees of freedom, are incredibly flexible, and are easily integrated into existing production environments. Payloads range from 3, 5, 12.5 and 16 kilograms, and the reach, from 500 to 1300 millimetres.
2. Fanuc
FANUC (Fuji Automatic Numerical Control) is a Japanese company offering robotics and automation products and services to help improve productivity and maintain a competitive edge. FANUC's cobot series comprises the CRX-10iA, CRX-10iA/L, CRX-20iA/L, and CRX-25iA models. Fanuc cobots are quick to install and easy to use. The Japanese cobots set a benchmark for reliability, ensuring sustainable productivity enhancement.
FANUC cobots guarantee a secure return on investment. Payloads range from 4-35 kilograms, and reach from 550-1813 millimetres.
3. Yaskawa
Yaskawa is the largest maker of industrial robots. The company's new cobot, Motoman HC20DT IP67, broadens the human-robot collaboration (HRC) spectrum. A unique feature of the Yaskawa cobot is that it performs under challenging settings such as machine tool loading, where the robot frequently comes in touch with cooling emulsions due to its dust- and waterproof protection class IP67. Payloads range up to 20 kilograms, and reach up to 1700 millimetres.
4. ABB
ABB robots are versatile; two cobots are synchronised to feed parts to another cobot. Suitable for small parts, different payloads, and sizes make it ideal for precise applications.
i. GoFa™ CRB 15000: It features integrated torque sensors in each of its six joints. Payload – up to 5 kg; and reach 950 mm with a Tool Center Point (TCP) speed of up to 2.2 m/s.
ii. SWIFTI™ CRB 1100: It can be programmed and configured easily with the help of the graphical SafeMove configurator App and the wizard easy programming software on the FlexPendant. Payload – up to 4 kg; and reach 580 mm, with TCP speed of over 5 m/s. This cobot is 5 times faster than any other 4 kg cobot.
iii. YuMi® - IRB 14000: With flexible hands, camera-based component positioning, parts feeding systems, and advanced robot control, this dual arm cobot is most suitable for small part assembly. Payload – 0.5 kg and reach – 559 mm
iv. IRB 14050 Single-arm YuMi®: This compact and lightweight (9.5 kg) cobot can be mounted in any position, be it on the wall, ceiling, or simply upright on a workbench. The ultra-light magnesium arm has seven axes and can move similarly to a human arm, providing more mobility than a classic 6-axis robot. Payload – 0.5 kg, and reach – 559 mm.
5. KUKA
Due to its sensitive technology, LBR iiwa cobot from KUKA can learn from its workers. This cobot can even document and optimise the results independently as it is connected to the cloud. Highly versatile, intuitive to operate, and reliable in contact with humans – the LBR iisy is a cobot for all production areas – most suitable where precision, speed, and agility are crucial. Payload ranges from 3 to 15 kg, and reach, from 760 to 1300 mm.
6. Franka Emika
This German cobot can operate like a human arm regarding maneuverability and sensitivity. Franka Emika's programming platform is a workflow-based software program and user-friendly, by arranging different actions into a sequence to teach the robot a complete task through demonstration and parameter adjustment. The torque sensors in all joints of the cobot make it extremely sensitive. Payload is up to 3 kg, and reach, up to 855 mm.
7. Techman Robot
Techman Cobots are the first to have an integrated vision system – the integrated camera at the robot arm's end and the associated programming interface feature smart recognition programs. Set tasks such as pattern recognition, object localisation, barcode scanning, and color recognition are relatively simpler. The software is easy to use by someone without programming knowledge. Four different cobots are on the market: the TM5-700, TM5-900, TM12 and TM14. Payload ranges from 4 to 14 kg, and reach, from 700 to 1300 mm.
I hope the above preliminary information and features of cobots from the different manufacturers will inspire MSME manufacturers to think of plant automation with cobots.
Conclusion
Across the globe, manufacturers use automation to increase productivity, alleviate labour shortages and improve product quality. Collaborative robots offer a cost-effective, adaptable and safe automation option. Cobots can collaborate with people without wearing protective devices. In-built sensors and cameras ensure the robot doesn't injure human workers in the vicinity. Unlike standard industrial robots, it is simple to program, that's the major factor most suitable for MSME organisations. It can learn new actions using mobile applications and user-friendly software. Workers can also manually position a collaborative robot and store the settings in the software.
In recent years cobot technology has progressed to the point that they are now accessible and inexpensive to small businesses.
Darshana Thakkar is MSME Transformation Specialist and Founder, Transformation – The Strategy Hub. An Electrical Engineer followed by MBA – Operations with hardcore industry experience in managing business operations, Darshana is an expert in transformation of businesses that helps them achieve growth with speed and scale. She has invested 27 years in transforming Micro and Small Enterprises. Her rich experience in resolving pain areas and the MSME/SME industry's real-life problems are helping the organisation for quick results.
Darshana has helped many MSMEs to increase profitability & achieve sustainable growth. She is keen on the growth of Indian Startups, providing mentoring and hand-holding support to startups to make them succeed quickly.
She is very passionate about supporting women in pursuing their career and life goals. She is actively working for women's entrepreneurship and leadership development.
She is:
• Founder and CEO of Transformation
• Certified Women Director by IICA, Ministry of Corporate Affairs, Government of India
• Empanel and recognised Startup mentor and Trainer by CED, Government of Gujarat
• Registered and Verified Business Advisor – Tata Nexarc, Tata Business HUB, Mumbai, and
• Chairperson: MSME Support & PRO at Makarpura GIDC Association, Vadodara.
MSME Transformation and Strategic Advisor – MSME Business Forum India, Darshana has received various accolades:
• Winner of Gujarat Women's leader award 2022 by CMO Asia
• Winner of Influential Women leader in business by Insight Success 2022
• Recognised as India's most trusted consulting company by Insight Success 2022
• Felicitated by Mentor my board in the gracious presence of Honourable FM Mrs. Nirmala Sitaraman during Women Director's conclave – 2022
• Felicitated by the president of Makarpura GIDC Association during the Suvarna Jayanti Mahotsav on 17th December 2022 for her excellent contribution in supporting MSME and startup Businesses.
Apart from this, she is an author and publishes her blog, article, and case study related to the industry. Email: [email protected]
