Robotics in Manufacturing: Transforming Production

Key Points

• Robotics combines computer science, engineering and technology to design, build and operate robots that can perform tasks traditionally done by humans.
• Robotics and automation go hand-in-hand. Automation uses robotics technology to make processes run automatically with little human intervention.
• Robotics is crucial in modern manufacturing, enhancing efficiency, precision and safety across various industries.
• Robots in manufacturing excel at repetitive and precise tasks like welding, painting, assembling, sorting, machine tending, drilling, grinding and more.  

• Common types of robots in manufacturing include SCARA, articulated, cartesian, delta and cylindrical.

Have you ever wondered how cars, electronics and gadgets keep technologically advancing?

Part of the answer is robotics in manufacturing. It’s sped up processes, freed people from time-consuming tasks to focus on innovation, improved precision and boosted output! These are only a few ways robotics has revolutionized manufactured goods.   

Keep reading to learn more about robotics in manufacturing, including exactly what it is, how it got started and how you can contribute to this exciting field!

What Is Robotics?

Robotics combines computer science, engineering and technology to design, build and operate robots that can perform tasks traditionally done by humans. These machines can range from simple mechanical arms to advanced units capable of complex operations and basic decision-making.

Robotics has taken the manufacturing industry by storm, helping various sectors automate tasks to enhance productivity and safety while reducing costly errors.

How robotics helps automate manufacturing tasks

Robotics and automation go hand-in-hand. Without robotics, automation opportunities would be limited. Without automation, robots would have little value.

Automation uses technology to make processes run automatically, with little to no human intervention, minimizing manual effort. There are four different types of automation:

1. Fixed: Designed for repetitive, high-volume production tasks.
2. Programmable: A system that can be reprogrammed for different tasks. It is best for batch production processes where product variations are common.  
3. Flexible: Independently adapts to various tasks with minimal downtime and setup. This system is designed for environments that manufacture various product types.
4. Integrated: Combines multiple automation processes into one seamless system. This is the most efficient form of automation.

Robotics in Manufacturing History

Some people still think of tired Industrial Revolution workers when they hear the word “manufacturing.” But did you know we’re currently in the fourth wave of the manufacturing evolution with the fifth on the horizon?

Robots didn't enter manufacturing until the early 1960s, during the third wave. The first industrial robot was invented by George Devol and named Unimate. Unimate was installed at a General Motors plant in 1961 and performed simple tasks like moving pieces of metal from one place to another.

Over the decades, robots have evolved to handle more complex tasks, integrating sophisticated technology and artificial intelligence.

How are robots used in manufacturing today?

Robots are incredibly versatile and their use spans various industries.

Robotics in automotive manufacturing is vital. Within this sector, robots perform welding, painting and assembling parts. In the aerospace sector, robots handle precision tasks like drilling and fastening. The food manufacturing industry uses robots for packaging and sorting, while the electronics industry relies on them for assembling tiny, delicate components.

Let’s dive a bit deeper into the specific tasks robots in manufacturing perform.

Tasks robots in manufacturing perform  

Robots excel at repetitive and precise tasks like:

• Welding: Robots perform welding tasks with high precision and consistency, reducing the risk of errors and enhancing the quality of welds in repetitive or hazardous environments.
• Painting: Robotic systems apply uniform coats of paint, reducing waste and exposure to harmful fumes.
• Drilling: Robots execute drilling operations with exact precision and repeatability, minimizing human error.
• Grinding: Robots handle grinding tasks by maintaining consistent pressure and movement, resulting in high-quality finishes.
• Sorting: Robotic systems sort items based on predefined criteria, streamlining the organization of parts and materials, and improving the overall workflow.
• Assembly: Robots assist in assembly processes by accurately positioning and fastening components while enhancing production time and reliability.
• Pick-and-place: Pick-and-place robots automate the handling of parts or products from one location to another.
• Quality assurance: Robots have advanced sensors and vision systems that conduct thorough inspections, ensuring products meet stringent quality standards.
• Transporting: Automated guided vehicles (AGVs) or autonomous mobile robots (AMRs) transport materials and products within manufacturing facilities, optimizing logistics and reducing manual labor.
• Material handling: Robots move raw materials or finished goods efficiently and safely, reducing the risk of injury.
• Palletizing: Robotic palletizers stack and organize products onto pallets, streamlining the packaging process and preparing items for shipment quickly.
• Packing products: Robots automate the packing process by accurately placing products into packaging, sealing containers and preparing them for distribution.
• Machine tending: Robots perform machine tending by loading and unloading parts from machines, ensuring continuous operation and reducing downtime in manufacturing environments.

Types of Robots in Manufacturing

Several types of robots make performing otherwise time-consuming and labor-intensive tasks possible. Within manufacturing, common types of robots include SCARA, articulated, cartesian, Delta and cylindrical.

SCARA robots

Selective Compliance Assembly Robot Arm (SCARA) robots are ideal for pick-and-place tasks due to their horizontal movement capabilities. These robots excel in high-speed assembly, packaging and material handling applications where precision and repeatability are crucial, making them perfect for electronic component insertion and palletizing.

Articulated robots

These robots have rotating joints, typically ranging from two to ten or more axes, making them highly flexible and able to perform complex tasks. Articulated robots are commonly used for welding, painting, assembly and material handling due to their ability to mimic human arm movements and access hard-to-reach areas.

Cartesian robots

Also known as linear robots, these operate on three linear axes (X, Y, and Z) and are great for tasks like CNC machining, 3D printing and pick-and-place operations. Cartesian robots offer high accuracy and repeatability, making them suitable for applications that require precise positioning and straightforward movements within a defined rectangular workspace.

Delta robots

With a triangular configuration, Delta robots are perfect for high-speed pick-and-place tasks, packaging and sorting applications. Their parallel arms provide speed and precision, allowing for rapid handling of lightweight materials in industries such as food processing and pharmaceuticals.

Cylindrical robots

Operating within a cylindrical area, these robots utilize a combination of rotational and linear movements to perform tasks like assembly and handling at high speeds. Cylindrical robots are efficient in material transfer, spot welding and machine loading/unloading, offering a good balance of reach and compact footprint.

Pros and Cons of Robots in Manufacturing  

Like any technology, robots come with their own set of advantages and challenges. Understanding these can help manufacturers make informed decisions about integrating robotics into their operations.

Benefits of robots in manufacturing

• Increased efficiency: Robots work faster than humans, boosting production rates and reducing cycle times. This increased efficiency allows for higher output and the ability to meet tight deadlines, enhancing overall productivity and competitiveness in the market.
• Consistency: Robots perform tasks with high precision and repeatability, ensuring uniformity in product quality. This level of consistency minimizes errors and defects, leading to fewer reworks and higher customer satisfaction, which are critical factors in maintaining a strong brand reputation.
• Safety: Robots handle dangerous tasks, reducing workplace injuries and improving overall safety in manufacturing environments. By taking over hazardous activities such as heavy lifting, welding and exposure to harmful substances, robots help maintain a safer work environment while also potentially lowering costs.

Challenges and considerations

• High initial cost: Investing in robotics can be expensive, requiring substantial upfront capital. While the long-term benefits often justify the investment, the initial financial burden can be a significant barrier for small to medium-sized enterprises looking to overcome.
• Maintenance: Robots require regular maintenance. Scheduled upkeep, including software updates and mechanical repairs, is essential to prevent unexpected downtime and costly interruptions in production. Manufacturers must factor in these ongoing expenses when calculating the total cost of ownership.
• Skill gap: Workers need training to operate and manage robots, presenting a challenge in skill development and education. The advancement of robotics in manufacturing necessitates a workforce equipped with robotics and automation skills.

Robotics in Manufacturing: Emerging Technologies

As mentioned above, the fifth wave of the manufacturing evolution is on the horizon! Known as Industry 5.0, or the fifth Industrial Revolution, this wave is defined by a human-centric approach. The following technologies are making it all possible.

Collaborative robots

Collaborative robots in manufacturing, also known as cobots, are designed to work safely alongside human workers, enhancing productivity by leveraging human dexterity and decision-making with robotic precision and endurance. These robots are equipped with advanced sensors and AI to ensure safe interaction, adaptability and seamless integration into various tasks ranging from assembly to quality control.

Machine learning and artificial intelligence

Machine learning and artificial intelligence empower robots to analyze real-time data, learn from their experiences and make autonomous decisions as they’re presented. In manufacturing, AI-driven robots optimize production processes, improve predictive maintenance and enable adaptive quality control.

Computer vision

Computer vision technology enables robots to interpret and understand visual information from the surrounding environment. This allows robots to perform complex tasks such as inspection, sorting and assembly with high accuracy. In manufacturing, computer vision enhances defect detection, automates quality assurance and facilitates precise identification and handling of components. It also presents opportunities for safety features, prompting a robot to stop working when a human is nearby.

Robotic process automation

Robotic process automation is software that helps robots automate repetitive and rule-based tasks, streamlining workflows and reducing operational costs. Robotic process automation in manufacturing can be applied to inventory management, order processing and data entry, freeing human workers to focus on more strategic and creative activities.

FAQs

How do robots impact job opportunities in the manufacturing industry?

While robots can replace some manual jobs, they also create new opportunities in programming, maintenance and management. The key is to upskill workers to handle these new roles. A robotics and automation education program can help bridge the gap.¹

How big of a role does robotics play in manufacturing?

Robotics is crucial in modern manufacturing, enhancing efficiency, precision and safety across various industries. As technology advances, so does the need for skilled robotics technicians.

What industry uses robots the most?

The automotive industry uses robots the most, relying on them for intricate tasks like welding, painting and assembly.

Learn More About Robotics in Manufacturing

Whether you’re interested in robotics in manufacturing or already working in manufacturing and want to gain skills that will keep you up to date, Universal Technical Institute can help.

Our 51-week Robotics & Automation Technician program teaches students electrical, mechanical and programming skills valuable to the ever-evolving manufacturing sector. Our curriculum prepares students for this high-tech industry, and graduates can return for no-cost refresher courses.³⁹ Ready to invest in yourself?

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