Jeff Burnstein, President, Association for Advancing Automation (A3).

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

Companies are adopting industrial and collaborative robots at a record pace in part because they are becoming so much easier to use. Software companies are creating no-code or easy-to-program platforms that can handle repetitive tasks, freeing up human workers to focus on more complex and valuable work.

Artificial intelligence is creating more potential robot applications that improve decision-making processes and enhance efficiency. AI-powered robots can learn and adapt to their environments, making them more versatile and effective for any number of tasks.

Mobile robots are taking off in manufacturing industries for tasks such as material handling, inventory management, and logistics. These robots are equipped with sensors and navigation systems to move autonomously in dynamic environments to reduce the need for human intervention. While many companies are working on humanoid robots, it could be years, even decades, before those are prolific in factories or in homes.

Manufacturers are increasingly recognising the benefits of automating their material transport with mobile robots that can flexibly and safely move materials and goods within their plants. A3 doesn’t track mobile robot orders, but in a recent report, Interact Analysis said mobile robot shipments grew by 53% in 2022 and forecasts “an installed base of over 4 million mobile robots by the end of 2027, 1.5 million of which will be installed in 2027 alone.”

 

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

The efficiency and productivity benefits industrial robots and collaborative robot applications bring are extensive, especially when you consider how difficult it has been over the last few years to hire and retain employees to do many of the dull, dirty, and dangerous tasks that are perfectly suited for robotic automation. Robots offer:

·         Increased speed and precision as they can perform repetitive tasks at a much faster pace and with greater accuracy than human workers. This in turn leads to increased production speed and quality output.

·         Reduction of downtime because they can work continuously without breaks or rest, leading to reduced downtime and increased overall production output.

·         Flexibility and adaptability because they can be easily reprogrammed and reconfigured to perform different tasks or adapt to changing production needs.

·         Improved safety since they can handle dangerous or hazardous tasks that may be unsafe for human workers.

 

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

Whether planning internally or with an integrator or vendor, manufacturers first need to identify tasks that can be automated; often these include the dull, dirty and dangerous ones that are so difficult to fill with human workers. They must then assess the existing workflow to identify opportunities for automation integration, making sure to consider factors such as space limitations, production cycles, and human-robot collaboration. 

Next step is to choose the right technology. Select the appropriate robot technology based on the specific requirements of the workflow. Consider factors such as payload capacity, reach, flexibility, and safety features.

Finally, monitor and optimise performance by regularly monitoring the performance of robots in the workflow and adjust as needed to optimise efficiency and productivity. The integration of robots into existing workflows can maximise their potential benefits and minimise any negative impacts on human workers.

 

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

Workers tasked with managing robots may need advanced programming skills, but we’re increasingly seeing smarter and easier-to-use robots that don’t require programming skills at all. This means more organisations can automate, especially small-and medium-sized companies that are new to automation and often hesitant to automate at all because they think they do not have the in-house capabilities to handle complicated programming and set-up tasks.

Without requiring coding, vendors or integrators or even the manufacturer itself can deploy these robots – some including in a packaged solution – in just hours or days.

That doesn’t mean workers operating or working alongside robots don’t need any skills to manage these robots. They should learn problem-solving skills to troubleshoot minor issues before needing to contact a vendor’s service and support teams. They need to learn the robot’s key functionalities, including alert signals (whether different sounds or colours) – and always follow them to ensure they and colleagues are always safe when interacting with the robots.

 

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

Some manufacturers have created their own specialised training programs that focus on the skills needed to operate and maintain robotic automation systems. The programs include hands-on training, online courses and certification programs. Robot vendors also offer these programs.

Some manufacturers also send their workers to schools or institutes such as the eKentucky Advanced Manufacturing Institute (eKAMI). Often these schools partner with the manufacturer to ensure the workers are getting the right training on the exact robotics they will be working with.

Manufacturers also send their employees to tradeshows and conferences such as Automate, the largest robotics and automation trade show in North America (May 6-9, 2024, in Chicago). These events typically have educational sessions for all things related to robot deployment, workflows, tips and tricks, etc. Attendees can interact side-by-side with automation experts who know how to implement, optimise, and expand automation – giving insights to put into practice right away.

Overall, manufacturers are taking a proactive approach to address the need for training and upskilling their workforce to better handle the increased use of robotics. By investing in training programs, collaborating with educational institutions, and providing ongoing support, manufacturers can ensure their workforce is equipped with the skills needed to succeed.

 

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

Traditional industrial robots and collaborative robots can perform repetitive and dangerous tasks with high precision and efficiency, allowing for faster production turnaround times and increased flexibility in workflow planning. The industrial robots are typically installed in one location and programmed for a single repetitive application while the collaborative robots can be moved and reprogrammed as production needs change.

Both have advantages, and manufacturers need to choose which to use based on the requirements of the application, not the type of robot. Most manufacturers have a combination of robots to fit their needs, allowing them to stay competitive in an ever-changing market landscape.

 

Jeff Burnstein is President of the Association for Advancing Automation (A3), the leading North American trade group representing over 1160 global companies involved in robotics, artificial intelligence, vision, motion control and related automation technologies. Burnstein joined the association in 1983 and has held a variety of senior positions, culminating in his promotion to President in 2007. He is a frequent commentator in the media, often discusses automation issues with policy makers, and regularly speaks at global conferences on issues such as global automation trends, the impact of automation on jobs and the future of automation beyond the factory floor. Burnstein also serves on the Executive Board of the International Federation of Robotics (IFR). He was recently honoured with the Engelberger Award for Leadership, considered the ‘Nobel Prize of Robotics’.

 

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