Collaborative robots have emerged as a transformative technology, driving improvements in safety, quality, delivery and cost-efficiency across operations of all scales. Yet, they’re not a universal remedy.
Collaborative robots, often referred to as cobots, are specialised robotic systems designed to work alongside humans in a shared workspace.
Unlike traditional industrial robots, which are usually placed in cages or restricted areas to ensure safety, collaborative robots are engineered to operate safely and interact directly with human workers.
These robots are equipped with advanced sensors and safety features that allow them to detect and respond to human presence, ensuring a level of cooperation and coordination between humans and machines. This enables them to perform tasks that require precision, strength or consistency, while also benefiting from human decision-making and adaptability.
Most collaborative robots are designed to be user-friendly and easy to programme, with intuitive and accessible interfaces. This allows non-experts to set up and modify tasks, making them more accessible to a wider range of users. This ease of programming also enables cobots to be quickly reconfigured and redeployed to different tasks or areas of a production line.
Cobots have a wide range of applications and are especially useful for tasks like assembly, material handling, quality inspection and other processes that benefit from human-robot collaboration.
One company reaping the benefits of collaborative robots is Cummins, a global leader in the design, manufacture, supply and servicing of engines, filtration and power generation technologies.
The cobot above is supplied by FANUC and located at the Cummins Darlington Engine Plant. It is being used to help manage part proliferation and improve quality.
Cummins has a significant presence globally, employing around 70,000 people across almost 200 countries. In the UK, they employ 5,500 people in 16 locations, including large manufacturing facilities in Darlington, Daventry, Huddersfield and Cumbria, alongside a heavy-duty battery R&D facility in Milton Keynes.
While the company was already implementing cobots before the pandemic, these efforts were expedited and Cummins now has more than 300 cobots supporting dozens of manufacturing capabilities across sites globally.
Steven Grace is Cummins’ Global Manufacturing Automaton and Technology Leader. During a recent Monthly Industry Meetup, Steven was invited by Made Member FANUC, a leader in cobot solutions, to share Cummins’ journey, successes and pitfalls of adding value to manufacturing with cobots.
Less than 50% of Cummins’ cobots have been deployed in what Steven referred to as “pure collaborative applications,” emphasising the importance of selecting the right technology for specific tasks. A great example is the Darlington engine plant, one of Cummins’ most progressive sites in terms of deploying robotic technology.
A trio of cobot success stories:
1. Oil Pan Assembly – previously a three-person job, this task now involves two collaborative robots working closely with one operator. This application highlights the seamless integration of cobots within confined spaces, demonstrating their potential for enhancing productivity and efficiency.
2. Process Cleanliness – Cummins tackled the repetitive and monotonous task of cleaning engine pallets by pairing a cobot with a vacuum cleaner to ensure consistent cleanliness. Every pallet is cleaned every time it gets to the head of the line. This simple yet effective solution demonstrates the quick deployment and proximity to human workers that cobots offer.
3. Machine Tending – Cobots have also been used to automate existing processes, such as opening machine doors, changing over components, closing the door and pressing Cycle Start. In certain scenarios, one cobot can tend to multiple machines, enabling labour to be redeployed where most needed.
“A word of caution,” Steven noted. “The key with any robotic automation deployment is understanding the application that you want to improve in the first place.”
It’s essential to weigh various factors when considering collaborative robots, he continued. Payload, cycle speed, form factor and movement restrictions all play a role in determining whether a cobot is the best solution.
Safety considerations are especially paramount, as tasks involving heavy loads, sharp objects or movements at head height may warrant a different approach.
“Collaborative robots are great. They are flexible and, in many cases, they are easy to deploy, but they aren’t the right solution for every application. Don’t get miss-sold a cobot application when you might be better served by another route,” Steven warned.
“One of the great things about cobots is how easy they can be to programme. Some can even self-programme. We have a site in North America using self-programming welding robots that can be quickly reconfigured to weld different canisters. Yet, programming traditional industrial robots has also become easier. The technology has cross-pollinated.”
Additionally, while collaborative robots are more flexible and are particularly well-suited to fast-changing dynamic manufacturing environments, they can also be 30% to 40% more expensive than their industrial counterparts.
Understanding your application, collaborating with the right integration partner and selecting the appropriate technology are crucial to harnessing their full potential, concluded Steven.
Safety first
Following Steven’s talk, a Discussion Group of a dozen Made Members further explored the cost-effectiveness, skill requirements and safety concerns surrounding collaborative robots.
There were concerns regarding the skill level required. Many collaborative robots are being sold as ‘DIY’ level technology which isn’t always true. Members experienced with cobots noted that in many cases, the skills required were more ‘pro-level DIY’ – i.e. plumbing in a new sink rather than painting a wall.
Another issue raised by several Members centred on misdeployment, with one noting how a cobot was chosen because of increased worker safety yet it would have been better, cheaper and easier to simply guard the process in question.
The understanding that cobots are equipped with various safety features and technologies to ensure safe interaction with humans can potentially lead to complacency.
As one Director commented; “Even though collaborative robots are designed with safety features and are generally considered safe, it's still important to conduct a thorough risk assessment to identify and mitigate any potential hazards specific to the work environment. This ensures that safety measures are in place to protect both human workers and the equipment itself.”
Safety assurance and compliance is an area where choosing the right integration partner pays off. Their expertise, experience, and commitment to safety and efficiency can significantly impact the outcome of your cobot implementation.
Small manufacturers typically don’t have the knowledge or experience to understand the nuances and challenges specific to different applications, or when a cobot could and should be used.
The right partner can also tailor the cobot solutions to meet the specific needs and requirements of a particular business, especially important when looking to fit the technology into an existing process or workflow. They can also optimise the cobots programming and understand how best to utilise its full capabilities, maximising potential productivity gains.
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*All images courtesy of FANUC / Cummins