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A 2016 study conducted by Aberdeen Strategy & Research found that a single hour of unplanned downtime cost organizations an average of $260,000 - approximately $326,254 when adjusted for inflation. Further research indicated that, at that time, around 23% of unplanned downtime was caused by user errors in the manufacturing industry, compared to 9% in other industries.
The leading cause of downtime is the number of machinery operators that need to be trained properly. However, the use of robotics minimizes this risk thanks to programming that can handle a huge range of jobs.
Using robots in manufacturing processes allows for a massive reduction in operations costs as well. For example, robots don't require light or heating and can work around the clock.
This increases the return on investment and annual revenue. And, with the average cost of robots decreasing significantly over the past decade, the return on investment is improving in leaps and bounds. On average, the time taken to recoup the cost of installing an Industrial robot is one to two years.
Human workers in production lines have to monitor every part they handle diligently. However, repetitive tasks like this are monotonous and tiring, causing all kinds of mistakes.
Robotic automation enables pre-programmed quality control, allowing Manufacturing robots to maintain a high standard of quality for each part produced. Additionally, Industrial robots equipped with cameras and other vision systems can spot flaws that may not be visible at first glance.
Installing or "employing" Industrial robots in hazardous environments shields human workers from harm. This could involve anything from lifting heavy objects to working with blades or lasers. These machines can also operate in environments where they're required to handle chemicals, which further reduces the risk of short- and long-term health issues for factory workers.
Another of the significant benefits of robotics in manufacturing is optimized production lines. By operating faster and with consistent quality, Industrial robots ensure a steady flow of production all year round.
They're also able to operate around the clock, increasing outputs exponentially and achieving a higher return on investment.
Designs, materials, and production processes are subject to change, which impacts the flow of manufacturing lines. This change can cause disruptions in employee output as staff are retrained to adapt to new requirements.
Industrial robots can be programmed to adjust to new production requirements without skipping a beat. Some systems are even capable of storing multiple programs for quick switching.
This frees up employees to learn skills for more advanced jobs in the production line.
Human errors are reduced as Industrial robots ensure a consistent output with no alteration to their operations. As mentioned above, this gives employees the opportunity to handle tasks requiring more nuanced human input.
Roles in the manufacturing process that require constant repetition can be handled without any errors by robotic automation. This reduces possible variations or faults that could be caused by something as simple as a slip of the wrist.
Industrial robotics circumvent the need for lunch breaks, retraining, and sick leave. They can work in confined spaces, allowing the number of robots in any given line to be maximized.
This reduction in labor costs far outweighs the initial investment required to install robotic automation, allowing companies to remain competitive as they adapt to changes in manufacturing protocol and standards.
Despite these benefits, using robots in manufacturing isn't without its downsides.
While their cost can be recuperated quickly, the initial outlay for adopting Industrial robotics is high. Unfortunately, smaller factories may not be able to take advantage of this tech until it becomes more affordable.
As of today, most robots are ideal for repetitive tasks, making them somewhat limited in their functionalities in the production line. Human employees are still responsible for more complex work and decision-making.
Unless you're implementing a plug-and-play system, the expertise required to program and automate these robots may be costly.
Robots have two main benefits in this industry:
At present, the industries benefiting the most from robotic automation are:
Repetitive and precision tasks in these sectors are easier to execute with the help of robotics.
Thanks to consistent advancement and innovation, the manufacturing industry is set to benefit greatly from the following developments:
There's no doubt that Industrial robots have revamped operations and boosted efficiency for manufacturers of all sizes, across various industries. From increased production to reduced manufacturing costs and fewer human mistakes, robotic automation has allowed for streamlined processes.
Ultimately, robot automation is not something to be feared. "Employing" Collaborative robots to work alongside humans will minimize errors and injuries while allowing employees to shift to higher-skill roles - a win-win situation.