End-of-arm tools knocking down the barriers to manufacturing automation
Author : By Thomas Knudsen, General Manager Northern Europe, OnRobot
24 July 2019
The manufacturing industry is constantly evolving, with technological advances in automation enabling businesses to reach new levels of productivity across all sectors. For example, a recent report by ING revealed that robot use within food manufacturing in Europe has increased by 50% in the past five years.
Manufacturers are seeking ways to increase their output in order to satisfy the rising consumer demand – and this trend is only set to continue: BCC Research forecasts that the global robotics market will be worth $64.0 Billion by 2023.
Meanwhile, political uncertainty alongside a skills shortage risks putting the UK on the backfoot of this revolution. As the industry becomes increasingly competitive, manufacturing businesses must look into implementing automation solutions in order to keep up with the competition.
However, change is always difficult. Adopting different and innovative strategies comes with a series of obstacles which manufacturers are working to overcome. According to a survey conducted by L.E.K. consulting, one third of decision makers within the manufacturing industry feel that they lack the capital to invest in automation. A traditional industrial robot alone costs from £40,000 to £64,000. Add on the price of customised parts, accessories and the implementation process itself, the figures can be astronomical.
Cost isn’t the only factor getting in the way of robotic innovation. The same survey also uncovered a certain scepticism towards automation and whether this will actually bring a significant return on investment – as stated by 31% of manufacturers surveyed.
Finally, factory managers are concerned that their teams lack the necessary skills to utilise the robots.
While these are all valid objections for traditional industrial robots, developments with collaborative robots (cobots) have completely changed the playing field. Cheaper, more intuitive and boasting a greater degree of flexibility, they have automation a far more viable option for SMEs.
Step one: a helping hand
Firstly, it must be said that robotic arms and cobots tend to be a more affordable and convenient solution compared to traditional robots due to their reduced size. As well as this, robotic arms can be fitted with special tools that play a crucial role in the robot’s efficiency.
Just as a car would be purposeless without its wheels, a robot needs its ‘hand’ to be effective. End-of-arm tools are robotic manipulators attached to the extremity of the robot’s arm, designed to enable the robot to perform a series of functions such as picking, packaging, assembling, or collecting information. Also known as robot end effectors, they allow the robot to interact with the environment or with the item at hand.
When it comes to robotic automation, manufacturers tend to fear the challenges that a complex set-up process can present. Hiring specialised programmers can be costly and time consuming. EOAT’s and pre-programmed robots help cut costs associated with the set-up by simplifying the implementation even for operators without a robot programming background. Some current models also feature a graphical user-interface (GUI) which allows operators to easily familiarise themselves with basic to advanced programming.
Step two: all about flexibility
Understandably, manufacturers using legacy systems that do their job are likely to be reluctant to implementing new solutions which can be costly and risky. So, in order to feel more secure while embracing innovation, they must identify ways to minimise the investment and ensure this is worth their while.
EOAT’s allow manufacturers to reduce costs by only purchasing a limited number of robotic arms, as each one can be used to complete multiple actions simply by switching the end effector. The versatility of EOAT’s also increases automation efficacy, making robotic deployment even more advantageous.
For example, smart grippers, are ideal for delicate products, as they can detect item type and size and can therefore adapt their grip the item’s dimension and handle it without damaging it. Robust sensors generate alarms to correct a robot’s positioning, while tool changers allow for quick and easy switching from one tool to another, enabling the robot to adjust to different item types and phases of the production cycle.
Step three: check and review
Trying out a new strategy also means reviewing it and evaluating whether the investment has paid off. Productivity analysis is critical to a factory’s success, as it allows a business to identify potential areas of improvement and eliminate errors. This is one of the processes immensely facilitated by intelligent EOAT’s: these devices possess smart hardware and software which help collect and analyse data and deliver performance feedback.
As more and more organisations adopt automated solutions, manufacturers don’t have a choice but to consider joining this trend if they want to remain competitive. All innovation comes with risk but, if businesses carefully choose the best end-of-arm tooling options, based on their production needs and available resources, they are set to gain exceptional benefits from deploying these revolutionary tools.
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