[webinar] Embracing Digital Transformation in Maintenance & Plant Operations | March 10 at 1pm EST – Register Now

Robotics in Manufacturing

Elizabeth Ruiz, Editor, Maintenance World

Posted 7/17/2024

Introduction

Starting with the first robotic arm in 1961, robotics have been used in manufacturing to expedite processes and improve safety in factories. Today’s more advanced (and affordable) automation robots are capable of many more tasks than when they first came about. They help plants, mills, and mines all over the world enhance productivity, accuracy, repeatability, and quality. Companies investing in robotics are experiencing a high ROI and improved planning strategies using the data they can provide. (1)

How are robotics used in manufacturing? What are the pros and cons to robotics in manufacturing? How can robotics be used for better reliability and maintenance? What are some good maintenance tips to take care of the robotics in your organization? Let’s find out in this week’s newsletter. 

robots in manufacturing facility robotic arms

How are Robotics used in Manufacturing?

Robotics are being applied in many industries including automotive, electronics, aerospace, and metal/plastics. (3) In general, manufacturers use robots for adaptive or flexible applications, for example pairing them with remote monitoring to be able to make adjustments off-site. They can also be used to automate and streamline tasks such as material handling, assembly, welding, and palletization. (1) Robotics is essential in the evolution of Industry 4.0. It contributes to digital transformation of manufacturing processes and makes smart factories possible (3)

Robotics improve safety in manufacturing by taking on tasks including high volumes of materials and repetitive tasks which are easy to be distracted while doing. This also improves accuracy, avoiding human error. Vanson Bourne found that 23% of unplanned downtime in manufacturing happens due to human error. 

Collaborative robots (cobots) can work alongside human counterparts on the floor, making work execution more accurate and efficient. They are also being increasingly used for lights-out manufacturing. (2) They are equipped with safety features and sensors to assist people in tasks requiring extreme precision, strength, or endurance while keeping workers safe. Other types of robots working in factories today are articulated robots, SCARA robots, Delta robots, Cartesian robots, mobile robots and polar robots. (3)

Industry 4.0 innovations in robotics are enhancing their capabilities in many new ways. Robotics are being developed with the senses of touch, sight, and hearing to complete tasks they couldn’t before. For example, some robots contain Light Detection and Ranging (LiDAR) sensors, enabling depth perception and object location by using laser reflections (similar to echolocation in bats). (2)

Another way in which robotics are helping the manufacturing industry is addressing labor shortages. With new technologies, the demand for skilled workers is increasing. With robotics, people working in plants, mills, and mines have more time to spend on tasks requiring critical thinking and problem solving as opposed to repetitive and labor-intensive tasks. (3)

Pros and Cons of Robotics in Manufacturing

Pros

There are many advantages in using robotics in manufacturing. We already mentioned some such as safety, automation and making up for labor shortages. Let’s explore some of the further benefits. 

Robotics can reduce costs pertaining to maintenance, operations, energy, quality control, and inventory holding; increase productivity; and reduce time-to-market for products. They boast a high ROI, improve reliability (more on this later), allow for more precision and objectivity performing detailed tasks, and provide more opportunities for employee growth in the organization. (4) (2) 

Expanding on this…

They allow for more flexibility because they can be adapted to perform a wide variety of tasks such as quality inspection, dispensing, pick and place, and screwdriving – without taking time for training. 

Because they are available 24/7, they can help increase production along with making up for labor shortages. Decreasing equipment downtime is also a factor in production efficiency. 

Robotics in manufacturing can increase employee satisfaction by helping with strenuous or dangerous tasks and allowing them to spend more time building skills that can help them get promoted within their companies. (5)

Cons

Of course, there will be challenges that come with using robotics, just as with anything else. Although robotics improves safety in many areas, there are still physical safety risks from employees working closely with large and powerful robots. Proper training is vital for technicians working with robots on the floor, which will take up considerable time and resources. 

Safety tips include installing warning devices, barriers, and interlocks around robot systems; mark the maximum reach of a robot with safety tape or paint on the floor; locate emergency stop buttons around the robot system; and ensure operators read and understand robot system documentation.  (2) (8)

While robotics are filling in some of the blanks in labor shortages, there could be job loss due to the ability of organizations to eliminate certain positions in favor of robots. Lastly, despite advances, robots do have limited capabilities when executing human-like tasks. Although there is a good ROI from using robotics, the initial cost of implementation can be high. (2)

Robotics in Reliability and Maintenance

As mentioned previously, human error is inevitable. It plays a part in safety incidents, production loss, and downtime. Workers can become distracted and tired, large in part due to the fact that it is not physically or mentally easy for people to repeat the same tasks over and over shift after shift. Small errors can have a huge effect on product quality in the end.

Collaborative robots can help solve this problem with the ability to repeat a task with no deviation. (5)

Automation in maintenance management provided by robotics increase productivity by taking care of simple tasks for workers, such as vibration checks, oil sampling, and meter reading – and perform the tasks accurately. 

Data sensors that perform condition monitoring can semi-automate maintenance scheduling. Time-based tasks can be created automatically, while maintenance managers can create an operation in which maintenance software will automatically generate work orders. 

Optimized data from robots facilitates reporting on operational maintenance costs, performance, and inventory stock. This way, maintenance managers know which assets get the most observation and how maintenance hours are spent – allowing them to make better decisions.

Condition monitoring data has evolved the abilities of predictive analytics as well. This information can be used to very accurately predict when a part or component will fail. This reduces unnecessary tasks, and therefore the overall maintenance workload. (6)

Robotics Reliability and Maintenance Tips

Just like the equipment that robots assist with, they require preventive maintenance (and performance measurement) to keep them up and running and performing their tasks correctly. Plants, mills, and mines should develop strict guidelines and maintenance schedules to ensure peak performance. This includes installation, upkeep, continuous improvement, retrofitting or redeployment, and more. (7)

Like any other asset, robots can suffer from contamination, component wear, misalignment, etc. Proper maintenance is necessary to avoid breakdowns and unscheduled downtime. Organizations need to have a robot maintenance plan in place to avoid this and increase lifespan. Making sure robots are maintained properly makes them safer to work with and avoid injury. And again, like any other asset, PM frequency will vary from robot to robot. Make sure to refer to their maintenance manuals for the right information to schedule PMs. (8)

robotics in manufacturing

According to eWorkOrders‘ Ultimate Guide & Checklist for Optimal Robot Maintenance, basic guidelines for best practices in robot preventive maintenance include:

Daily Checks – visual inspection, cleanliness, lubrication, check battery level, check sensors, software updates, test run

Monthly Checks – power system, drivetrain, control system, end effectors, safety systems, cleaning, programming, ventilation, back-up memory, visual inspection in motion

Quarterly Checks – check batteries, check joints, check sensors, check wiring, lubricate moving parts, check the software, check all connections, check the unit cables, tighten bolts (very important!), detail clean the mechanical unit

Annual Checks – replace batteries, replace grease and oil, inspect brake operation, check all unit cables, check the wiring, tighten all bolts, detail clean the mechanical unit, inspect joints and bearings, inspect sensors, check the software, complete functional tests (8)

Consider the following Robot Preventive Maintenance Checklist (eWorkOrders) to include in your routine inspections of the robots in your organization:

  • Monitor the robot’s motion and inspect its harness, cables, and structure
  • Listen for excessive noise or vibrations
  • Examine the backup controller’s memory
  • Verify proper brake functioning
  • Inspect the teach pendant
  • Evaluate the robot’s repeatability
  • Tighten any external bolts
  • Check for defective seals and signs of grease or oil leakage
  • Remove any chips or debris from the robot
  • Lubricate joints, bushings, and balancer housing
  • Test the batteries in both the controller and robot arm, and replace them if necessary
  • Clean the vents and cooling fans using compressed air, and replace any filters if necessary
  • Clean the light curtains and sensors.
  • Verify the integrity of any grippers, end-effectors, or tooling attached to the robot arm
  • Inspect any fixtures or mounting hardware that the robot interacts with
  • Check the condition of the robot’s drive belts or other motion components
  • Verify the accuracy of any sensors or vision systems used by the robot
  • Clean and recalibrate any force-torque sensors
  • Check the condition of any pneumatic or hydraulic hoses and connections
  • Inspect the condition of any machine vision lenses or cameras
  • Verify the calibration and accuracy of any laser trackers or other measurement devices used for robot positioning
  • Check the condition of any custom software or scripts used to program the robot
  • Verify the functionality of any interlocks or safety devices, such as emergency stop buttons or light curtains
  • Conduct any required software updates or firmware upgrades for the robot controller or peripheral equipment
  • Verify that the robot is properly grounded and that all electrical connections are tight and secure. (8)

Conclusion

Robotics have revolutionized manufacturing by enhancing productivity, accuracy, and safety. They are vital in various tasks, from assembly to quality inspection, and are essential to the Industry 4.0 transformation. The benefits, including improved efficiency and reduced human error, are significant, but challenges such as high initial costs, potential job displacement, and the need for proper training remain. A proper reliability and maintenance program is crucial for optimal performance and longevity. By effectively leveraging robotics, manufacturers can boost reliability, drive growth, and maintain a competitive edge.


Sources

1) How the Manufacturing Industry Uses Robotics & Automation. JR Automation blog

2) Impact of Robotics in Manufacturing. MANTEC blog

3) Robots in the Manufacturing Industry. Types and Applications. Hamza Wasim. May 4, 2023. Wevolver blog.

4) How Small Manufacturers are Building a Business Case for Robotics. Louis Columbus, Senior Industry Marketing Manager, DELMIA. April 4, 2024. Manufacturing.net.

5) What is Industrial Automation? March 3, 2021. Universal Robots.

6) Uses of Robotics in Maintenance Management. January 22, 2022. Eagle Technology. SME blog.

7) Proactive Steps for Robot Reliability and Safety. January 1, 2023. Industrial Machinery Digest blog.

8) The Ultimate Guide & Checklist for Optimal Robot Maintenance. eWorkOrders blog.


Looking for a midweek break? Keep up with the latest news brought to you every Wednesday by the Maintenance World crew.

Picture of Brawley

Brawley

Join the discussion

Click here to join the Maintenance and Reliability Information Exchange, where readers and authors share articles, opinions, and more.

"*" indicates required fields

This field is for validation purposes and should be left unchanged.

Get Weekly Maintenance Tips

delivered straight to your inbox

"*" indicates required fields

This field is for validation purposes and should be left unchanged.