Revolutionising Manufacturing: The Role of Robotics
Published on : Tuesday 06-06-2023
Researchers are exploring ways to make robots more collaborative and perform end-to-end tasks, says Sunil David.
During the 3rd Industrial Revolution in the 1950s and which reached its peak in the late 1990s, manufacturing industries across the world underwent significant change – one of which was the introduction of robots and automation on the shop floor. The primary purpose was to increase productivity and reduce operating costs. Over the last few decades as we are currently in the 4th Industrial Revolution, the integration of Robotics in manufacturing has transformed the industry, revolutionising production processes and driving efficiency to unprecedented levels.
Robotics in manufacturing is being used in multiple different areas due to automation. Robot applications in manufacturing include welding, assembly, shipping, handling raw materials, and product packing. For this reason, multiple manufacturers are leveraging robotic automation for an increased number of tasks. Today, robots collaborate with human workers (cobots) on almost all tasks on the shop floor or in a warehouse. Robotics in manufacturing is widely being used for repeated tasks and to streamline the assembly workflow. Many industries involve three types of work – Dull, Dirty and Dangerous, and it is here that robots can play a huge role in carrying out dangerous and voluminous tasks and thus protect and ensure safety of human workers. Moreover, human workers can suffer from fatigue and get distracted over long shift hours, potentially leading to injury or error. The use of robots in manufacturing can help these industries reduce and remove such mistakes because of their high level of precision and accuracy.
Robotic process automation (RPA) is a widely used software technology powered by AI with multiple use cases across different industries including manufacturing. Such robots can attempt to emulate human minds, accelerate operations, and ensure transformation of business processes. RPA can be a key enabler within the supply chain, collaborating with back-office operations and IT systems to ensure quick completion of repetitive tasks like purchase management orders and invoice processing.
The key benefits of robotics are as follows:
Robotics can save time and costs
Robot applications in manufacturing today take less time and lower investments to produce compared to the past. Robots are equipped with quality improvements and controlled safety requirements built into state-of-the-art facilities, reducing labour expenses and unplanned downtime, and they can also work continuously, boosting output significantly and reducing downtime.
Robots can be scaled up or down for specific production needs
Robots may be scaled up or down to be deployed in enterprises that have specific production needs depending on order volumes. They are used in high production, high volume applications as well as in low to medium-volume industrial settings. Due to advancements in technology robots may now be swiftly programmed and set up for new tasks and can be deployed in several locations across production plants. Robotics has expedited production processes, allowing for higher volumes of output within shorter timeframes and thus enhances productivity.
Robots can enhance precision and accuracy
Within the manufacturing industry there is a lot of emphasis on ensuring quality control so as to ensure products are manufactured with zero defects and no wastage. Robots have improved quality control through precise and consistent operations, minimising errors and defects.
Robots improve workplace safety
Since Robots can perform hazardous tasks, it goes a long way in ensuring worker safety, and thus reducing the risk of accidents and injuries which is extremely important.
Robots are easily programmable
There are currently two simple ways to program robots. The first method which is known as offline programming, enables a user to model a whole cell or work area and create the series of actions needed to complete a specific task. The second method is with a teach pendant, where a programmer or engineer directs the robot via a series of actions. The instructions can then be saved and changed as needed.
Robotics can create new jobs
Robotic automation also helps create new jobs in manufacturing in areas of programming, engineering, end-effector design, operators, data analysts, and in robots manufacturing and systems integration. To assist with machine maintenance, human workers are needed.
The main application of robotics in the manufacturing industry is as follows:
Material handling
From large containers to blood samples, robots are used today to handle a continually expanding range of materials, primarily stable or hazardous. This technique also reduces the risks of injury to human employees because the robots never become tired or make errors while carrying out their basic tasks. Robots can now do more tasks, which imply that employees can now be redeployed to more complex processes and value added works and this is bound to increase employee experience.
Picking, packing and palletizing
After the product has been manufactured, picking and packaging robots can carry out a variety of tasks. These robots quickly choose individual parts, pack them appropriately, and palletize them. Robotic picking and packing can boost your production with accuracy since they can choose and pack items faster.
Loading of machinery
Robots that load and unload machinery are widely used in manufacturing line tasks involving the loading and unloading of parts. It may become increasingly challenging and dangerous for human workers to load and unload parts from a machine. Robotic machine loading will enhance output, safeguard your employees from potential harm, and eliminate tiresome, repetitive labour.
Assembly
Assembling together product pieces takes a lot of time and effort, and errors in judgement, boredom, and other uncontrolled variables can easily derail the assembly line process and thus impact production. A robot can substitute such a system, streamlining procedures and drastically lowering the likelihood of errors. Additionally, this allows the assembly process' human components to concentrate on the key aspect of quality.
Welding
Heat and pressure are used to connect metal components, which is an extremely risky operation that demands flawless accuracy. The production process might be hampered, the metal component can be ruined, and major harm can occur from the slightest welding error. Due to these factors, robots are increasingly being used for welding tasks.
Painting
Industrial paint robots are widely used in the automobile sector to uniformly paint components and equipment without leaving paint drips or markings. They are accurate, ensure every drop of paint is used, and apply the precise quantity to each piece of machinery. Industrial painting robots are made to be thin and flexible enough to go into nooks and crannies that would be challenging and time-consuming for human painters to access.
Adoption of robots globally and in India
According to the World Robotics 2021 Industrial Robots report published by the International Federation of Robotics (IFR), a record 3 million industrial robots operated in factories worldwide, with an increase of 10% from 2020. The sale of new robots grew slightly at 0.5% despite the global pandemic, with 384,000 units shipped globally in 2020. The IFR estimated global robot installations to rebound strongly and grow by 27% in 2022, exceeding the record level achieved in 2021. A new record of 486,800 units was installed globally in 2022 – an increase of 27% compared to 2021. Asia/Australia saw the largest growth in demand: installations were up 33%, reaching 354,500 units. The Americas increased by 27%, with 49,400 units sold. Europe saw double-digit growth of 15%, with 78,000 units installed.
There were less than 100 robots made annually for industries in India about 15 years ago, and now we are seeing approximately 5,000 to 6,000 robots built every year. The automotive and pharma industries are investing heavily in industrial automation. The capital expenditure is high, while labour costs are low but automation is inevitable now in order for the Indian manufacturing industry to be competitive in the global market. While automotive companies like Maruti, M&M, Tata Motors, BMW, Hyundai, etc., have been early using robots in their factories and are scaling up use of these robots as their production volumes increase, there are manufacturers like JSW Steel, ABB (a manufacturer of robots), Sterling and Wilson, Ola, etc., who have deployed robots on their shop floors and are clearly seeing the benefits. For example, in the ABB Smart Factory in Neelamangala in Karnataka, the company has been able to achieve productivity improvement of upto 100% with 30% less space.
Conclusion
Researchers are exploring ways to make robots more collaborative and perform end-to-end tasks. And with the advent of AI and powered by 5G Networks, robots in manufacturing are collecting data and helping manufacturers make better decisions for the future and help them in their manufacturing process. This also requires human workers on the shop floor to upskill and learn to collaborate and work with robots to ensure they are far more productive and efficient. Overall, the future of robotics looks very promising and is bound to revolutionise the manufacturing industry in times to come.
Sunil David has 28 years of experience in the IT and Telecom industry of which close to 20 years was with AT&T, one of the top Communication Service Providers of the World and a Global Fortune 100 Firm. Until recently, Sunil was the Regional Director (IoT) India and ASEAN for AT&T India where he was responsible for building the IoT strategy, Sales, Business Development and also worked on building a robust IoT partner ecosystem; and was also actively involved in a number of marketing initiatives to help enhance the AT&T brand in the IoT space. In his new phase of life, Sunil is Advising and Consulting AI and IoT Startups that are aspiring for the next level of growth.
Sunil has been a recipient of a number of Awards and Recognitions including 6 awards in 2021 and 3 this year from various Industry bodies and media conglomerates in recognition for his work in Digital Technology advocacy, Digital Skilling initiatives, contributing inputs towards IoT policy creation for India and for contribution to National Institute of Electronics and Info Tech, an Autonomous Scientific Society of MeITY, Ministry of Electronics and IT, Govt of India for contributing inputs on the syllabus and specific courses in the Emerging tech space (IoT, Cloud, AI ) that needs to be incorporated into the Curriculum of State and Central Govt Universities. NASSCOM Foundation and IBM India have also planted tree saplings in Sunil’s name for his contribution to the Tech Industry.
