Industrial Automation Magazine India

Robots and humans complement each other and can always increase productivity

Published on : Tuesday 02-04-2024

Neelesh Chipade, Head – Product Marketing for Servo, Motion and Robotic Solutions, Mitsubishi Electric India.

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

The global industrial robotics market is growing quickly. Market volume is expected to surpass USD 45 billion by 2028, with a growth rate of approximately 3.83% annually. As robotic technology advances, there is a growing interest in automation, which is being driven by global labour shortage and a need for sustainable manufacturing. Also, the decrease in cost per robot makes automation more accessible and economically viable. Further, post-Covid-19 and amid geopolitical tensions, countries are boosting investments in robotics to facilitate the reshoring or nearshoring of manufacturing. Together, these elements fuel the growth of the industrial robotics market.

In modern automation, this expansion is reshaping the landscape of manufacturing in India. Manufacturers are investing in advanced automation technologies, integrating robots with artificial intelligence, predictive maintenance functions, machine learning, and computer vision to improve decision-making processes and increase adaptability in dynamic environments. The integration of IoT in manufacturing processes has enabled better connectivity and communication between robotic systems. This facilitates real-time monitoring, predictive maintenance, and data-driven decision-making.

Mitsubishi Electric India’s MELFA-FR Series of industrial robots provide new, more intelligent solutions that under-pin “next-generation manufacturing” that offers a simpler approach to more advanced and flexible production. These robots are capable of handling the modern-day automation needs.

 

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

Robots and collaborative robots (cobots) play significant roles in increasing efficiency and productivity in manufacturing by automating various tasks and enhancing overall production processes. They contribute to increased efficiency and productivity in manufacturing by providing precision, speed, continuous operation, cost and time savings, flexibility, improved safety, data-driven insights, and consistent output. These factors collectively enhance the overall competitiveness and sustainability of manufacturing operations.

The MELFA-FR Series of Industrial Robots offer next-generation intelligent functions that make it simple to carry out the work which has always defied automation. Mitsubishi Electric India’s MELFA Smart Plus offers greater accuracy and shorter startup times, making installation simpler and more advanced tasks possible. Sophisticated force sensors and enhanced cooperation with vision sensors are made much simpler with MELFA Smart Plus.

 

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

Integrating robots and cobots (collaborative robots) into existing workflows can be a complex process, but when done effectively, it can lead to increased efficiency, productivity, and job satisfaction. Collaborative human-machine operation support that includes safety options allow working areas to be jointly used by people and robots.

A comprehensive range of safety functions, including position and speed monitoring and monitoring of the X, Y and Z components, allow work to be conducted in collaboration with people. By following application safety steps, manufacturers can maximise the benefits of integrating robots and cobots into their work processes, creating a symbiotic relationship between automation and human labour. When implemented thoughtfully, automation can enhance productivity, create new job opportunities, and improve overall business competitiveness which helps in the upliftment, advancement and growth of humans as well as the work processes.

Collaborative robots are designed to work alongside human workers, which are well in demand and have seen a rise in popularity. These robots are designed to be more flexible and can safely interact with humans in shared workspaces, enhancing productivity and efficiency.

Robots do not necessarily eliminate human operators. Instead, they transform job roles. For example, in manufacturing, robots can handle repetitive assembly tasks, freeing up human workers to engage in quality control, problem-solving, and other higher-level activities. While robots are making significant strides in various industries, the replacement of manual labour remains a complex and multifaceted issue as human working and strategy making is a crucial part which is hard to replace any day. Alongside working of Robots and Humans complements each other and can always increase productivity and enhance the work output and quality. Balancing technological advancements with needs of the workforce is crucial for a sustainable future.

 

What skills are required for workers to effectively operate and collaborate with robots or cobots?

Modern cobots do not require any complex programming languages. For example, Mitsubishi Electric’s Collaborative Robot “ASSISTA” can be programmed with a simple tablet. The tablet-based programming allows the following:

·         Easy and intuitive control of an industrial robot by operators without specialised training

·         Program movement of the industrial robot in an easy and intuitive way (task-based) by workers without specialised education

·         Make corrections in the control programs without stopping the robot

·         Reduce the number of cables by using wireless, touchscreen tablets, and

·         Development and modification of robot’s control programs using a simulation in an offline mode; this increases a programmer’s safety, reduces costs and speeds up the software development process.

 

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

Manufacturers are actively addressing the need for training and upskilling their workforce in the era of robotic automation to ensure a smooth transition, maximise the benefits of automation, and empower employees to work alongside new technologies. In addition to conventional methods of classroom training the manufacturers are also adopting the virtual reality (VR) based training modules where the candidate can learn the training modules by using VR glasses.

However, on the other side due to declining workforces in ageing societies such as Japan, securing sufficient human resources is becoming increasingly difficult, which in turn is raising the demand for AI that can support efficient mechanised operations. The new AI technology achieves quick stepwise learning with the help of “MAISART” reinforcement-learning capability, a significant improvement over conventional methods that require enormous learning time to test various content and their combinations. To shorten the takt time using production equipment such as industrial robots, skilled workers conventionally must make many adjustments to the production equipment. With Mitsubishi Electric’s new AI, however, adjustments of route, speed, acceleration, etc., are performed automatically. Action is learned beforehand using a simulator, allowing the AI to make adjustments automatically to shorten the takt without using an image sensor. The result is productivity equal to or higher than that of equipment adjusted by a skilled worker.

 

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

Robots play a significant role in enhancing the flexibility and adaptability of manufacturing processes.

Robots can be programmed and reprogrammed to perform a variety of tasks, making them highly flexible in adapting different production requirements. Robots excel at handling diverse tasks and materials, enabling manufacturers to easily switch between different product lines and accommodate changes in dynamic and complex product designs. This flexibility is crucial in industries where customisation and quick adaptation to the market demands are essential.

Modern robots often come equipped with adaptive control systems and sensors that allow them to respond to variations in the production environment. This adaptability enables robots to make real-time adjustments, ensuring precision and quality even in dynamic manufacturing settings.

Robots contribute to the flexibility of manufacturing by automating material handling tasks, such as sorting, packaging, and transportation. Automated material handling systems allow efficient and adaptable workflows in response to changes in production requirements.

Mitsubishi Electric Cobot “ASSISTA” offers a wide variety of components grippers, fingers, vision and other peripherals developed by a group of organisations known as MELFA Robot Partners. These tools can easily be setup and configured for your applications. ASSISTA can also be configured to move freely as part of an AGV/AMR or as a mobile robot. The operating buttons on the robot arm provide easy control for ASSISTA and the teaching pendant for programming and guidance is no longer needed. The LED on the robot arm displays the current status of the robot.

Mitsubishi Electric’s MELFA-FR Series of intelligent robots incorporates advanced technologies and Smart Manufacturing solution “e-F@ctory”, which demonstrate proven capabilities at Mitsubishi Electric India’s own production facilities. These go beyond basic robotic performance to find ways of reducing the Total cost of Ownership (TCO) in everything from planning and design to operation and maintenance.

 

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

 

Neelesh Chipade is Head – Product Marketing, responsible for Servo, Motion and Robotic Solutions at Mitsubishi Electric India. Neelesh is Bachelor of Engineering in Instrumentation & Control from Vishwakarma Institute of technology Pune with Diploma in Business Management from Pune. His professional experience spans over 20 years in the Automation Industry. He started his career as project Engineer and worked on machines and DCS projects for the initial period of career. Later he sailed through different departments in engineering, sales & marketing at Pan India Level in various companies. With this he is having experience across various industries in the Automation sector.

In current role he is responsible for Products marketing for Servo, Motion and Robots giving Mechatronics & Robotics solutions to different industries. He is also working for positioning the solutions for EMS (Electronic Manufacturing Sector).He also worked in Mitsubishi Electric Corporation Japan in the Global marketing section for products & solution developments. 

 

 

Reference

MAISART: -Mitsubishi Electric's AI creates the State-of-the- ART in Technology