By James McKew
The vast majority of manufacturers in Asia are leveraging Industry 4.0 technologies such as robotics and automation to increase productivity and assisting human activities. For manufacturers who have implemented industrial automation with collaborative robots (cobots), many rejoiced with the prospect of being able to use a robot without any external safety measures such as fences (upon risk assessment) or the flexible deployment of robots. While these factors are certainly a game-changer, there is another more tangible aspect that cobots have brought to the factory floor; its ease of use.
Looking back, one thing has stayed consistent in the robotics industry. It takes a well-trained person to properly program an industrial robotic or motion control solution. Even when robot and motion manufacturers announce addition of new setup wizards or some other shortcuts with simplifies programming, the fact remains that someone with little or no training cannot walk up to the controller, and within minutes, have a usable program written and running with minimal instructions. Configuring traditional robotic and motion control solutions are enough to leave non-programmers in despair, much less successfully writing a functional program. Regardless of the format or the programming language, if a multi-axis motion solution or robot was sold to customers who did not have any prior experience, it is essential for the customer to attend factory training or have an engineer guide them.
For comparison, let us step back and look at another software intensive technology, the cell phone. 20 years ago, a brand new phone will be accompanied by a paper manual that weighed just as much as the phone. Yet, this was for a phone that only stored phone numbers and made calls. Today, despite purchasing a handheld device that is vastly more capable than the PCs that were available in the 1990s, a quick start guide is barely provided. Why? This is because the software and the interface allow users to access all that power intuitively.
Nonetheless, this does not suggest that programming a robot with multiple logic threads and error handling is something that can be distilled down to the same level as learning how to play simple mobile games. However, for the basics, there is absolutely no reason it should take two weeks of factory training to learn how to program a robot to perform a simple machine tending solution.
One forward-thinking person who agreed with this premise and took action was Esben Østergaard, a PhD student. Esben wanted to develop robotic technology which could address real-world production requirements without the traditional headaches, and a scalable solution with a lower cost of entry which Small to Medium Size Enterprises can easily adopt. This was the birth of Universal Robots and cobots that are not only safe, but intuitive. Anyone with the skills to use a smartphone, can most likely figure out how to use a cobot. This single feature brought about quite a number of significant benefits for companies such as Bajaj Auto Ltd. Although manufacturers were not confident in leveraging the new robotic technology, the awareness about the benefits of cobots was gradually rising in Asia. The global automotive manufacturer, Bajaj Auto Ltd, becomes India’s first cobot user in 2010. The employees in Bajaj Auto Ltd highlighted that due to the flexibility of cobots, operating the advanced technology has become very easy.
For a start, programming cost adds to the upfront cost of a new robotic implementation. By minimising programming time, it is a direct improvement to return of investment. Ease of programming also means that less technical support is required, and employee(s) previously doing the automated task can be repurposed into robot deployers. An easily programmable system can, therefore, act as a labour multiplier.
Given enough time, any system will need troubleshooting, debugging or fixing at some point. The loss of production caused by this downtime can detract from ROI, and often cause intangible drawbacks such as frustrated technicians. An easily serviceable solution can reduce downtime and improve ease of recovery.
Cost of training (for both programming and maintenance) can add up to a hefty sum if systems are complex. An intuitively programmable and easily serviceable platform mitigates this ramp up time, and greatly reduces the total cost of ownership of the system.
Similar to how internet has given a voice to anyone with a mobile device, the ease of use of cobots enables flexible automation in companies ranging from startups, SMEs, to Fortune 500 manufacturers, fuelling the next revolution in manufacturing. In fact, manufacturers in Asia are slowly scaling up by investing in smart automation. Cobots will continue to help manufacturers thrive in the Asian industries.
James McKew is Regional Director at Asia-Pacific Universal Robots