Automated machine tending: Top 5 advantages

What is automated machine tending?

Automated machine tending encompasses the transformation of manufacturing processes through robots and automation. 

This innovation turns the conventional operation of manufacturing equipment on its head, replacing the traditional reliance on human operators with software, robotic arms, and other tools. 

Previously, human operators managed and performed manufacturing tasks, including hazardous work and repetitive, mind-numbing jobs.

As a consequence, machine tending automation not only streamlines operations but also redefines labor dynamics, freeing skilled workers to focus on higher-value, more creative tasks.

Now, duties such as loading and unloading parts, inspecting components, and executing necessary adjustments or tool changes, are seamlessly handled by this emerging technology. 

Not only that, but with its rapidly increasing efficiency and affordability, even small businesses are finally allowed to catch up to bigger companies. 

Automated machine tending finds application in various mission-critical operations across manufacturing sectors.

Some of the most common use cases for automated machine tending are: 

• CNC milling machines
• Lathe operations
• Grinding machines
• Injection molding equipment
• 3D printing setups
• Press machines
• Robotic welding cells
• Automated assembly lines
• Laser cutting systems
• Industrial packaging machines

Automated machine tending virtually guarantees an ongoing and optimized workflow in the automotive, manufacturing, medical, and many more industries. 

However, not all types of automated machine tending systems are the same, as we’ll find out below. 

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Types of automated machine tending systems

There are several automated machine tending systems, and they often combine for a larger-than-the-sum-of-its-parts total. 

Here are the ones you should have on your radar: 

• Conveyor systems: The all-around workhorses of automated machine tending, efficiently transporting parts or materials to and from machines. By feeding components seamlessly into manufacturing processes and reducing manual intervention, they keep things going. 
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• ‍Gantry systems: Gantry systems are key for accurate material handling, precise positioning, and moving heavy (or even delicate) parts during manufacturing. They’re very versatile and capable of intricate movements, which makes them ideal for tasks that demand control down to a minute scale. 
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• ‍Automated Guided Vehicles (AGVs): AGVs streamline material transport within manufacturing facilities, navigating on their own to transport goods between workstations. Their main advantage is their flexibility, allowing them to efficiently ferry materials without fixed pathways.
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• ‍Robotic arms: Robotic arms are the Swiss Army knives of automated machine tending, flexibly able to execute diverse tasks such as loading, unloading, or extremely intricate assembly. Their adaptability and precision make them a must-have for modern manufacturing, especially in tasks that demand both strength and finesse.

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Top 5 advantages of machine tending automation

Yes, automated machine tending may be the answer to your wishes for scaling up your operations.

Here are the 5 major benefits of bringing a machine tending robot into the fray: 

Big productivity increases 

Automated systems can monitor your equipment around the clock while making real-time adjustments to increase performance. 

Also, machine tending robots don’t need breaks, don’t go to Ibiza in the summer, and won’t get distracted or fatigued, while requiring minimal maintenance. 

Prioritize worker safety with robotic handling

Automation allows robots to take over repetitive, strenuous, or hazardous tasks, such as handling hot materials or operating in confined spaces. 

This significantly reduces workplace accidents and injuries, creating a safer environment for human workers. 

Much better quality and consistency

Machine tending robots provide consistent, high-quality tending day in and day out. 

Their built-in ability for repetitiveness and accuracy also means a significant reduction in variability.

The net result is higher-quality products, fewer flaws, and increased standards under all conditions — including those that are hazardous for human operators.

Scalable operations

Your business will grow, so will demand, and automated systems can easily scale along with your needs.

They can monitor and control entire production lines without significant reconfiguration. Adding more machines or work cells won’t require you to go on expensive hiring sprees to find more people to operate them. 

This makes automated machine tending the perfect long-term solution for expanding your manufacturing productivity — especially with shifting market demands. 

Cost efficiency over time 

Maybe you’re thinking about upfront costs for robot arms and other automated machine tending systems. But that’s not keeping your eye on automation’s excellent ROI (typically 1-3 years).

What’s important to remember: Automating repetitive manual tasks eliminates the need for as many human operators, reducing overall labor costs. Plus, the extra productivity always ends up paying for itself. 

The systems also minimize errors and rework, reducing waste and saving materials. Additionally, maintenance costs are often lower, too, since the equipment experiences less downtime and fewer interruptions due to human error or improper usage.

Automated machine tending: Let’s talk about costs

Automated machine tending comes with several upfront costs.

Let’s take a look at the key points to consider before you break out your credit card.

Initial investment: Weighing the costs

Before diving in, it’s important to keep the financial landscape in mind. 

The out-of-pocket costs can be significant, often ranging from thousands to hundreds of thousands of dollars, depending on the complexity of your needs. 

For instance, a basic CNC loading robot might set you back around $25,000, while a sophisticated multi-axis robot with AI vision could climb to $250,000 or more. 

Of course, there are more affordable high-quality robot arms ranging from $15,000 to $35,000.

Installation and integration: First steps

Beyond the equipment itself, there are the additional costs of installation and integration, which typically eat up 10-20% of the equipment cost. 

This phase acts as the bridge between your existing operations and the automated future. Think of it like investing $2,500-$5,000 to seamlessly integrate that $25,000 robot into your workflow. 

Maintenance: Keeping things running

Like any complex system, automated machine tending equipment requires ongoing maintenance to make sure things keep running smoothly.

Think about allocating 5-10% of the equipment cost annually for service contracts, spare parts, software updates, and technician time for routine maintenance and troubleshooting. 

For a $25,000 robot, this translates to approximately $1,250-$2,500 per year — an investment in keeping your new robo-pal running smoothly and efficiently.

Additional overhead: Unseen costs

But that’s not all, because there may be unforeseen costs to keep in mind.

For instance, dedicate $1,000-$5,000 per robot for electrical power and pneumatic lines, along with additional cooling requirements. 

Then, optimize your floor space for the new arrival. Budgeting $500-$2,500 per linear foot for a conveyor system is not out of the question. 

Then, there’s training your employees to operate and oversee the automated processes effectively. This could cost $500-$1,500 per employee, but it's an investment in maximizing the potential of your robotic workforce.

Of course, some newer automated machine tending systems, like collaborative robots, tend to necessitate much less oversight and, therefore, much less human training.

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Time to implement automated machine tending

The key to implementing machine tending automation is building from a small base and scaling up as you gain experience.

• Assess what you need. Which machines and processes would benefit most from automation? Look for tasks that are repetitive, time-consuming, dangerous, down-and-dirty, or plain difficult for humans to perform. 
  
  Choose right. Explore the options for automating each process, from basic conveyors and pick-and-place robots to advanced AI and machine learning systems. 

• Shop around and get recommendations from others in your line of business. Be mindful of future needs and scalability as well as initial costs. 
  
  If you’re just starting or are a medium or small business, 6-axis robotic arms with automated machine tending capabilities tend to be the absolute best bang-for-your-buck option.

• Run pilot programs. Start with a small-scale pilot to test the automated systems on a few machines or production lines. Work out any issues and make adjustments before committing to a plant-wide rollout. 
  
  Train staff on how to properly operate and maintain the new equipment. Then, monitor productivity and quality closely to make sure you’re meeting all of your targets and no unplanned issues crop up.

• Keep optimizing. Automated machine tending is not a one-and-done process. Look for ways to keep streamlining processes and provide additional training as needed. 

Stay up-to-date with the most current advances in software, robotics, and AI that could enhance your systems, and even updates to your chosen robotic helpers. Even small tweaks can yield significant benefits. 

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Summing up

If staying competitive, increasing throughput and quality, and future-proofing your factory are priorities, then automated machine tending is worth a very serious look.

The technology is ready, and the benefits are real. Now, it’s just a matter of purchasing the right machine tending robot for you. 

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Next steps

RO1 by Standard Bots comes with everything you need to automate your machine tending applications on popular mills from Haas, Mazak, and more.

1. Affordable automation: RO1 is significantly more affordable than competing robots in its class and is available with both a 30-day on-site trial and ongoing leasing options.
2. Class-leading capability: RO1 leads its class with an impressive 18 kg payload, boasts a joint speed that's over twice as fast as the competition at 435 degrees per second, and offers superior precision with a repeatability of +/- 0.025mm.
3. Full machine tending solution: RO1 comes pre-packed with every accessory and gripper you need, alongside a simple configuration wizard and simulator — meaning your robot can be up and running within hours.

Speak with our solutions engineers today and get tailored advice on automating your machine shop with RO1.