Industrial Automation Magazine India

Robots and cobots do not replace human labour, they create additional opportunities

Published on : Tuesday 02-04-2024

Sameer Gandhi, Managing Director, Omron Automation, India.

What are the current global trends in the use of robots and cobots in manufacturing industries?

The manufacturing sector is witnessing a surge in both traditional industrial robots and collaborative robots. These trends are fueled by technological advancements, cost-effectiveness, and the need for greater automation and efficiency in production processes.

In 2021, the robotics industry witnessed a remarkable milestone with 517,385 new robotic installations worldwide. This surge is driven by various factors, including labour costs, skills shortages, and advancements in technology that make robots more affordable and user-friendly than ever before. The average robot density stands at 141 robots per 10,000 employees, translating to approximately 1 robot for every 71 employees. However, this density varies across different markets.

Collaborative and articulated robots with medium and high payload capacities have also seen significant growth rates (the growth rate in 2022 was 8%)

For Cobots – designed to work safely alongside human workers without safety barriers – also, there is a rapid growth. Between 2022 and 2030, cobot shipments worldwide are projected to increase exponentially, from around 4,500 in 2022 to 42,000 in 2030. Small and Medium Enterprises (SMEs): The increasing adoption of cobots is particularly notable in Small and Medium Enterprises (SMEs), where they enhance productivity and flexibility.

 

In what ways do robots and cobots contribute to increased efficiency and productivity in manufacturing?

Robots and cobots enhance manufacturing efficiency by increasing productivity, ensuring consistent quality, reducing downtime, improving safety, and offering flexibility as shown below:

• Increased Productivity & Quality: Repetitive, mundane, and ergonomically challenging tasks can be tedious and even dangerous for human workers. Robots and Cobots excel in handling such tasks. They work alongside humans, taking on dull and repetitive assignments. By doing so, they reduce human error, allow human workers to focus on more valuable tasks and thus significantly increase productivity levels. Robots also ensure consistent quality by eliminating variations caused by human factors.

• Reduced Downtime: Their continuous operation minimises production downtime, leading to increased overall efficiency.

• Improved Safety: Cobots are designed to collaborate with humans safely. They don’t require complex safety infrastructure or barriers. By handling hazardous tasks, they reduce the risk of workplace accidents and injuries.

 

How can manufacturers effectively integrate robots and cobots into existing workflows? Do these replace human labour or create additional opportunities?

Robots and cobots do not replace human labour entirely; instead, they create additional opportunities, enhance safety, and boost overall productivity when effectively integrated into existing workflows.

Some of the effective integration strategies are deep assessment of current workflows and identifying areas where automation can add value. The manufacturers should consider tasks that are repetitive, time-consuming, or pose safety risks and planning. Next is collaboration with robotics experts or consultants to design a customised automation plan. This is followed by training the workforce in operating and collaborating with robots. It is important to familiarise them with safety protocols and programming basics. Last but not the least is implementation, but this has to be done on a “gradual” basis. One should start with pilot projects to test the integration. And then gradually scale up based on successful outcomes.

 

How are manufacturers addressing the need for training and upskilling their workforce in the era of robotic automation?

In the era of robotic automation, manufacturers are actively addressing the need for training and upskilling their workforce via retraining and reskilling Programs, collaboration with education institutes, upskilling for new roles, etc. They also spend a lot of effort in anticipating and recognising the accelerating pace of enterprise-wide transformation and invest in critical skill development accordingly. Upskilling ensures that workers remain competitive and contribute effectively to the changing landscape of manufacturing.

 

How well do robots and cobots contribute to the flexibility and adaptability of manufacturing processes?

Robots and collaborative robots contribute to the flexibility and adaptability of manufacturing processes by mainly enabling quick changeovers, scalability, customisation, adaptability to variability, human-robot collaboration, and data-driven optimisation. These capabilities help manufacturers stay competitive, agile, and responsive to market dynamics and customer needs.

Robots can be programmed and reprogrammed to perform a variety of tasks, allowing manufacturers to quickly switch between different products or processes without significant retooling or downtime.  Collaborative robots are designed to be easily integrated into existing workflows and can be quickly reconfigured for different tasks or production setups. This rapid changeover capability helps manufacturers adapt to new product designs or variations with minimal disruption.

Robots can easily scale production output by adjusting operating parameters or adding more robots to the production line. This scalability allows manufacturers to ramp up or down production levels based on demand fluctuations, seasonal variations, or other factors.

By leveraging robotics, manufacturers can efficiently produce customised products at scale, offering greater flexibility to meet customer preferences and market demands. For example, collaborative robots are well-suited for tasks that require customisation or handling of individualised products. Also, they work alongside human operators and enable a flexible production environment where tasks can be easily shared between humans and robots based on their respective strengths. This collaboration enhances productivity, safety, and adaptability in manufacturing processes.

Robots equipped with sensors, vision systems, and AI algorithms can adapt to variations in raw materials, product dimensions, or environmental conditions. This adaptability ensures consistent quality and performance even in dynamic manufacturing environments. Another important insight is – robotics and automation systems generate vast amounts of data that can be analysed to optimise production processes in real time by leveraging the power of data analytics and AI.

 

(The views expressed in interviews are personal, not necessarily of the organisations represented.)

Sources:

https://blog.robotiq.com/robotics-in-2023-what-the-latest-world-robotics-report-tells-us

https://www.grandviewresearch.com/industry-analysis/collaborative-robots-market