Robots and cobots redefine manufacturing, blending precision and collaboration for Industry 5.0. With global trends favoring automation, they drive efficiency and adaptability, shaping the future of production.
Experts debate how robots and cobots contribute to manufacturing flexibility.
Robots today are performing far more extensively in the manufacturing industries than a decade earlier. The traditional industrial robots are better suited for tasks in fixed positions that demand high precision, speed, and payload capacity. The collaborative robots or cobots, are known for excellent flexibility, adaptability, and ease of use, and work in collaboration with human workers. Be they traditional industrial robots or the more recent collaborative cousins, their deployment relieves the human workers of tedious, repetitive jobs and frees them to engage in more creative pursuits. As the Industry 4.0 ecosystem matures and the shop floor becomes smarter, the digital transformation of the manufacturing processes would lead to increased productivity and better quality output. So what exactly are the current global trends in the use of robots and cobots in manufacturing industries?
“The current global trends for robots & cobots differ based on the industry which is looking for it, either manufacturing or R&D,” says Ayush Chadha, Business Development Manager, KUKA, who has valuable experience in robot installation, maintenance, and process programming for various applications. According to him, manufacturing industries expect easy to use machines which do not require a trained person to operate and the latest developments in the programming softwares of robots are based on UI based programming, which has programming blocks and essentially avoids the need to write any kind of syntax. R&D facilities, on the other hand, require easy integration and toolboxes in the operating software, which makes the connection of robot tools, third party softwares much easier. “For most applications which are developed in these facilities the focus is to engineer a unique application which requires software development for the main controller, like AI based machine vision or milling, the robot is a small part which is used to guide the tool and investing a lot of time in integration of different component is not ideal for them,” he explains.
According to Sameer Gandhi, Managing Director, Omron Automation India, 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. “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. For cobots – designed to work safely alongside human workers without safety barriers – also, there is a rapid growth. The increasing adoption of cobots is particularly notable in Small and Medium Enterprises (SMEs), where they enhance productivity and flexibility,” he avers.
“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,” says Neelesh Chipade, Head – Product Marketing for Servo, Motion and Robotic Solutions, Mitsubishi Electric India. In his view, 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. 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,” he elaborates.
To say that robots perform faster than human workers, is stating the obvious. They are also consistent in accuracy, leading to increased productivity and efficiency. Unlike human workers, robots work 24/7, need no rest or breaks and do not report sick! So let’s find out in what ways do robots and cobots contribute to increased efficiency and productivity in manufacturing?
“Incorporating robotics and automation solutions can furnish customers with the flexibility, agility, and adaptability requisite for their operations, thereby contributing to heightened efficiency. Although automation has traditionally been associated with the enhancement of productivity and quality, it has now risen to the status of a strategic requisite due to its user-friendly nature and ability to facilitate flexibility,” says Subrata Karmakar, President, Robotics & Discrete Automation, ABB India, who brings extensive experience in Robotics automation across market segments like automotive, metals, consumer segments, electronics and machine automation. “By utilising 3D vision algorithms, robots can offer greater speed, flexibility, and improved operational efficiency. The flexibility, combined with intelligence provided by the 3D vision system, makes them capable of performing various tasks such as sorting and loading small and disordered packages and packing large numbers of polygonal packages automatically. Thanks to their simple design and engineering, these robots can integrate quickly into production lines,” he explains.
Anuj Bihani, Managing Director, Alstrut India Private Limited, is a seasoned expert in the field of automation and robotics, holding a Master's degree in Manufacturing with specialisation in robotics. Alstrut is a leading partner of Universal Robots in India, which makes him eminently qualified to talk about cobots. “Cobots revolutionise manufacturing by fostering human-robot collaboration, driving efficiency, and productivity to new heights. Unlike traditional industrial robots, cobots are specifically designed to work alongside humans in shared workspaces, offering a unique blend of versatility and safety. Their collaborative nature empowers workers, augmenting their capabilities rather than replacing them. Cobots excel in tasks that demand precision, agility, and adaptability, seamlessly integrating into existing workflows without the need for extensive reconfiguration. With intuitive interfaces and simplified programming methods, cobots are accessible to workers with varying levels of technical expertise, ensuring rapid deployment and seamless integration,” he says.
“The growing adoption of robots and cobots in manufacturing is reshaping industries around the globe, revolutionising production lines, and unlocking new possibilities. These technologies play a powerful role in boosting efficiency and productivity within the manufacturing sector,” says Anshul Rathore, Product Architect (Mobile Robotics) at Addverb. Anshul has worked on a variety of products, ranging from autonomous cars to drones and mobile robots, all with a focus on integrating AI and automation into practical applications. According to him, robots have the following attributes:
∙ Automating Repetitive Tasks: Robots excel at repetitive tasks like welding, painting, and assembly, performing them consistently and tirelessly, also freeing up human workers for more complex activities that require judgment and creativity.
∙ Enhanced Accuracy and Consistency: Robots are programmed to perform tasks with high precision, minimising human error and ensuring consistent product quality. This reduction in defects translates to less rework and ultimately, higher yields.
∙ Increased Speed and Throughput: Robots can operate at faster speeds than humans, particularly for physically demanding tasks. This translates to a significant increase in production output and throughput within a given timeframe.
∙ Reduced Downtime: Robots minimise downtime and keep production lines running smoothly, leading to increased overall efficiency.
∙ Improved Worker Safety: Robots can take on hazardous tasks like handling heavy materials or working with dangerous chemicals.
By automating repetitive tasks, improving accuracy, and enabling continuous operation, robots and cobots significantly enhance efficiency and productivity in today's manufacturing facilities.
Integration of industrial robots, or cobots for that matter, into manufacturing processes can pose certain challenges to get the equation right. How can manufacturers effectively integrate robots and cobots into existing workflows?
“As manufacturing becomes competitive, businesses expand, needing more people to work for them. The most optimal way to balance this resourcing for manufacturing would be to deploy people for the uniquely human skills they have and leave the rest of repetitive work to robots. Recent OECD studies suggest that less than 10% of jobs can be fully automated, thereby limiting the number of jobs robots are likely to ‘steal’ away from human workers. This opens up new avenues of automation with a combination of Humans with Robots. Growing demand for cobots is a clear indication of this trend and hence in future we are more likely to see humans and robots working together on the factory floor rather than humans being replaced altogether,” says K Srinath, Vice President, Smart Manufacturing Business, Multivista Global Pvt Ltd, another dealer of Universal Robots in India. “Collaborative Industrial Robots as a technology is of great help in assisting humans in the manufacturing industry. Cobots are equipped with advanced sensors for fine-tuned work. They are quick to learn from the people who use them, becoming great co-workers and collaborators. So integrating collaborative robots has been easy and fast to implement,” he adds.
“If a robotic cell is built with required functionality it will do its job continuously. Today most of the industrial robots are doing this and in a caged/safety zone environment. We have several cobots working in low payload jobs together with humans around. This is getting adapted and there are many use cases. With mobile and service robots together with intelligent softwares, complex workflows are possible. This we see in warehouse automation, car manufacturing lines or assembly lines,” says Sunil Raibagi, Managing Director – Asia & VP – Strategy and Business Development, Zimmer GmbH, who has proven excellence in elevating business development activities for CNC controls and Automation & Robotics in multifarious customer segments in public as well as private sector. “Of course they are replacing human workers but also creating a lot of other jobs for programming, AI, maintenance and special development areas. This is creating never ending opportunities. So I say robots are getting jobs where human life is getting better and humans are getting creative jobs.
Adding to what has been stated above, Ayush Chadha points out that there are specific companies in India who are in the business of offering integration/engineering & consultation services who have an expertise in the different fields of integration such as mechanical & electrical commissioning, fabrication, PLC programming and robot programming. Not to forget, their teams also have process knowledge which helps them to deliver the solution with the best quality and understanding of the application which their customers have been pioneering in for many years. “Increase in automation as per my understanding is no threat to human jobs. In the past, unskilled labour was seen in factories doing repetitive or dangerous tasks where they were compensated with low incomes. New technology also creates new kinds of job roles as robot operators, programmers, and developers. This encourages people to learn new skills which increases their employability and standard of living,” he asserts.
When it comes to robotic automation, enterprises, especially the SMEs, are often apprehensive about the skills that their employees need to possess, apart from the initial investment which could be substantial. What skills are required for workers to effectively operate and collaborate with robots or cobots?
“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,” says Sameer Gandhi.
According to Neelesh Chipade, modern cobots do not require any complex programming languages. “For example, Mitsubishi Electric’s Collaborative Robot “ASSISTA” can be programmed with a simple tablet,” he says, elaborating how the tablet-based programming simplifies things, allowing 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.
Subrata Karmakar agrees and draws attention to the fact that cobots are based on lead-through programming, allowing even someone without specialised training to program the robot and have it running in minutes. This involves programming by demonstration, where a person guides the Cobot's arms and grippers through the required series of movements to perform a specific task, such as putting two objects together. These motions are recorded on an ordinary smart tablet through an interface with intuitive icons, creating a program. “This approach contrasts with traditional programming software, which requires each point-to-point movement to be recorded into a sequence. The ease-of-use of cobots removes a key entry barrier for new robot users and is particularly attractive to small and medium businesses that can benefit from their flexibility and scalability for growth,” he emphasises.
That brings us to the next question, how are manufacturers addressing the need for training and upskilling their workforce in the era of robotic automation?
“Manufacturers are addressing the need for training and upskilling their workforce in the era of robotic automation through various initiatives and programs,” says Anuj Bihani. “One notable effort by Alstrut India is the establishment of Universal Robots Authorised Training Centre, which provides curated certified training programs under the supervision of Universal Robots Denmark. This Authorised Training Centre at Chennai is the first of its kind in India, aimed at equipping workers with the necessary skills to operate and collaborate with cobots effectively. Additionally, manufacturers are investing in comprehensive training programs tailored to their specific automation needs. These programs cover a wide range of topics, including cobot operation, programming, maintenance, and safety protocols. Hands-on training sessions, simulations, and workshops are organised to provide practical experience and reinforce learning,” he elaborates.
“Global manufacturing is experiencing an increasing productivity dilemma. While firms race to capture retiring workers' expertise before they depart, integrating that knowledge with emerging technology, like robotics, is becoming increasingly difficult due to a growing skills gap. Globally, the World Economic Forum predicts a shortfall of more than 7 million qualified industrial workers by 2030,” says Anshul Rathore. According to him, manufacturers are addressing the requirement for training and upskilling their staff in the era of robotic automation using a range of strategies and initiatives:
∙ Training Programs and Workshops – geared primarily toward robotic automation.
∙ Internal Training Centres – here staff may obtain hands-on instruction and experience operating robots in a controlled setting.
∙ Partnerships with Educational Institutions – Create curricula and certification programs that are specific to the demands of the industry.
∙ Vendor Training Programs – intended to introduce workers to certain robotic systems and technology utilised in the production process.
∙ Safety Training – understanding how to operate robots properly, creating awareness of possible risks related to robotic automation.
“Overall, manufacturers understand the significance of investing in employee training and upskilling in order to successfully integrate robotic automation into their operations. Manufacturers want to enable their staff to use robotic technology efficiently and contribute to increased productivity and industry competitiveness by providing comprehensive training programs and chances for continuous learning.
How well do robots and cobots contribute to the flexibility and adaptability of manufacturing processes?
“We are moving from mass production, to mass customisation to mass personalisation. Mass customisation is good, but consumers want more. Hungry for products, services and experiences with a ‘human touch’ that lets them express themselves, consumers want not just mass customisation, but mass personalisation. We see this and related trends that involve giving products and services an individualised ‘human touch’ accelerating, and we believe that a future ‘Industry 5.0’ will revolve around putting even more of the human touch back into products,” explains K Srinath. “Flexibility and adaptability of manufacturing is key to enable mass personalisation. A well-designed robotic system brings in flexibility in your manufacturing for doing different tasks and enables you to scale to big improvement in your operations leading to mass personalisation,” he states.
To Sunil Raibagi, this is a big subject to discuss. “Mostly due to cameras, sensory devices and softwares we can handle it better than yesterday. Everyday there are many developments to make this job easier. Every manufacturing industry knows their processes well. This is then translated to requirements and adapted for robotic automation. You will find industry specific integrators focusing on this work on required functionality building. Continuous development has brought flexibility and adaptability for building required flexibility for industry-specific functions,” he opines.
“The robot is limited only by its ability to carry a certain payload and length of the arm, but if the base software of the robot offers you the freedom to run any application, then the adaptability of the robot increases exponentially,” says Ayush Chadha.
“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,” adds Sameer Gandhi.
Neelesh Chipade is of the view that 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,” he explains.
“The integration of cobots is anticipated to bring significant changes to the workplace of the future. With its digital features such as easy programming, cobots can be easily controlled and handled even by individuals without prior experience or expertise in robotics. This not only reduces installation costs but also requires minimal space, which is particularly beneficial in limited work environments, avers Subrata Karmakar.
Anuj Bihani notes that while both robots and cobots contribute to manufacturing flexibility, cobots offer distinct advantages in adaptability, scalability, and safety, making them indispensable assets for manufacturers seeking agile and responsive production capabilities in today's dynamic market landscape.
“Robots and cobots offer product customisation and personalisation by aiding efficient and accurate production processes, accommodating custom-designed items, and meeting consumer specific demands. With this, businesses can adopt agile manufacturing practices that emphasize flexibility, adaptability, and responsiveness to changing market demands, ultimately improving operational efficiency and competitiveness in today's dynamic business landscape,” notes Anshul Rathore.
“Industry 4.0 is a fascinating development in automation and is indeed worthy of its place in the history of the industrial revolutions that have taken place since the advent of water- and steam-powered mechanisation over a century ago. It is impossible to separate the birth of cobots from the evolution of robots in general and of robotic automation in particular. Because of this, cobots share a history and many ideas with the whole universe that the term Industry 4.0 is currently used to cover, says K Srinath. Still, the fundamental collaborative nature of cobots – the fact that they are designed to collaborate with human operators instead of eschewing workers the way that Industry 4.0 would – places cobots somehow outside, if not diametrically opposed to, the Industry 4.0 worldview. This difference – the cobot difference – exposes some significant limitations to the concept of today’s Industry 4.0, and at least points to something beyond it. Something that paves the way to Industry 5.0, he concludes.