How is Robotics Changing the Manufacturing Industry?

With the advent of Industry 4.0, the manufacturing industry underwent a massive change.  Industry 4.0, the new fourth industrial revolution supports organisational efficiency, and robotics is an important technology of Industry 4.0, which provides extensive capabilities in the field of manufacturing.

Robotics is gradually leading to the manufacturing of quality products. While the term Robotic automation has been making rounds in the industry for several years now, its capabilities or the significant changes it could bring to the manufacturing industry were never fully comprehended.

In the yesteryears, the term robotic automation was still quite alien and untrusted by many, and it was mostly deployed in industrial settings. But thanks to the accelerated growth and developments in hardware and software over the past decade, robotics has been incorporated into everything from augmented surgery and elderly care as well as in monitoring challenging environments. The mixing of traditional manufacturing processes with higher technology has led to greater production volumes and increased profits.

Robotics in manufacturing is used in different industries for various specific functions like welding, assembly, shipping, handling raw materials, and product packing. Robots can collect hidden, interesting manufacturing data as they operate closer to the component. This technology helps perform complex hazardous jobs, automate, sustain high temperatures, and work continuously for a long duration in assembly lines.

Before diving into the specifics and advantages of robotic automation and how it is helping the manufacturing industry, here is a small overview of its origin.

The Start – Origin

The word “robot” comes from the Czech word “Robotnik” which means “to slave”. Robots have been in existence since the early 1960s. George Devol submitted his first industrial robot patent in 1954. He built a robot that could transport things within a radius of 12 ft or less. His company Unimation (Universal Automation), founded in 1956, created UNIMATE, the first-ever robot utilised by one of the most prominent manufacturers, General Motors. This was followed by the creation of several other functional robots, but one noteworthy creation was made in 1978 by Vicarm and Unimation with the help of General Motors. PUMA! A robot arm was initially used in assembly lines and is still being used by robotic researchers.

The Present

The 1980’s saw a lot more advancement in the manufacturing industry with regard to robotics automation. Some of the significant inventions were as follows-

– A robotic arm created by Takeo Kanade with joint-mounted motors, in 1981

– In 1988, Yaskawa America Inc. introduced the Motorman ERC control system, with ongoing improvements until 1998 where the controller was improved to 27 axes and was able to synchronise up to four robots.

– FANUC robots introduced the first intelligent robot in 1992

According to RIA (Robotics Industries Association), around 160,000 robots were installed and operating in the U.S. in 2006. In 2005, around 20,000 robots which were valued at around $1.18 billion were shipped to North American companies. By the first three months of the year 2006, orders by RIA members were valued at $272 million, representing 3,722 such machines. Its obvious that the field of Robotics has been well-established for several years now and is fit enough to be called a mature industry with a future that is large and diverse and with a capability to grow infinitely.

Robotics in the Manufacturing Industry

Robots and co-bots (human workers) collaborate and co-work on almost all tasks in today’s time. The manufacturing industry is known for its labour-intensive and repetitive workload that requires a huge workforce. With the introduction of robotics in manufacturing, the former and latter are being handled by robots with more efficiency than ever before to strengthen and streamline the assembly process.

One of the best examples of an advanced robotics automation factory that was ever built is the Tesla Gigafactory, using the technology of self-navigating autonomous vehicles which were capable of free movement and shifting goods between workspaces.

Robotic process automation (RPA) is a technology that is being sought after across various sectors, capable of replicating human minds, accelerating operations, and transforming business processes.

A Capgemini study revealed that 91% of respondents claimed that RPA could play a big role for businesses by saving their time spent on tedious operations. 84% of people even believed that they could save considerable expenses.

What are the Main Applications of Robotics in the Manufacturing Industry?

1. Handling of Materials

2. Picking and Packing

3. Part transfer

4. Machine Loading

5. Assembly

6. Welding

7. Panting

8. Dispensing

9. Processing

Why is Robot Automation Considered a Competitive Business Solution in the Manufacturing Industry?

With the increase in sales, robot applications are no more a complicated affair. They now cost less and take less time to produce. Equipped with quality improvements and controlled safety requirements built into state-of-the-art facilities, they help save money on labour expenditures and work continuously, boosting output and reducing downtime.

What are the Benefits of Robotics in the Manufacturing Industry?

Scalability

Depending on the requirements, robots can be scaled down or up and deployed in industries that are running high-production or high-volume applications. Likewise, in low to medium-volume settings, modern robots can be deployed. With the recent improvements in the field, it is now easier to swiftly program them and set them up for new activities and can be employed in many locations across production plants.

Programmable

There are two ways to program robots. One is through offline programming which enables a user to model a whole cell or work area and create the series of actions needed to complete a task. The second is where a programmer or an engineer can direct the robot via a series of commands or actions.

Creates Jobs

Robotic automation can help create jobs in manufacturing such as programming, engineering, end-effector design, operators, data analysis, manufacturing of robots, and systems integration.

Safety and Speed

These are the most apparent benefits of using robotics. Heavy equipment, hot running machinery and sharp things, that can easily injure workers are undertaken by robots. Additionally, they are great when it comes to speed as they don’t require breaks or aren’t easily side-tracked like normal workers. They can operate continuously and speed up manufacturing.

Consistency and accuracy

Robots don’t split their focus among other things and are neither work dependent on the labour of others. They are constantly present and carry out their duties to the best of their ability. This helps deliver quality, as they are less prone to making mistakes.

Productivity

There is only so much a human can finish when it comes to physical tasks. But if you take some of the tasks off your human employees, they can be much more productive in doing various other tasks like interacting with consumers, responding to emails and comments on social media, assisting with branding and marketing, and selling goods, things that require a human touch.

What Types of Robots Used in the Manufacturing Industry?

• Articulated Robots– are mostly used for tasks that require versatility and dexterity.
• Cartesian Robots– are used to do tasks that include sealing, stacking, and exchanging tools, transport etc.
• Delta Robots- used for fast pick and pace transfer.
• SCARA Robots- used in pick and place or assembly operations where speed and accuracy is required.
• Cylindrical Robots- used in tight knit spaces due to their compact design, for tasks like machine testing, simple assembly, and coating applications.
• Polar Robots– used in manufacturing to lower production costs, increase productivity and reduce errors.

5 Industries that use Robotics in the Manufacturing Industry

1. Automotive– Robotics has had one of the most significant impacts on the automobile sector. Automation has been used in the industry for assembly lines for more than 50 years. They speed up production and complete repetitive activities faster and more precisely than humans.
2. Electronics and manufacturing- The ongoing demand for all electronic devices like cell phones, flat-screen TVs, and other gadgets has given room for manufacturers a lot of room for automation. Cobots (Human workers), essentially are used for their versatility in handling tasks and their ability to collaborate with humans effectively.
3. Medical- Robotic automation has immensely helped the medical sector. It has become so advanced that it has been successful in helping doctors perform precise procedures.
4. Food manufacturing- Robotics in the food and beverage industry helps to enhance product quality as they use machine vision sensors, cameras, and processing hardware and software algorithms to identify flaws in the production process.
5. Agriculture- The advancement of sensor technology has facilitated farmers to monitor illnesses and pests that have a detrimental influence on crop output. Automated systems are a common affair in today’s date, especially for undertaking tasks like weeding, spraying, and trimming.

The Future

The need to keep up with the competitive technological landscape is more than ever, and automation and robotics are a big part of it. They have become increasingly important for businesses to minimise human contact and remain competitive.

Researchers have been finding ways to make robots more collaborative and perform end-to-end tasks. The large scope of AI (Artificial Intelligence) robots in manufacturing is collecting data, streamlining the manufacturing process, and helping manufacturers make better decisions for the future. Robots have the ability to change the future in the coming years.