Modern industrial robots are employed in a wide range of industries, from semiconductors and autos to metal forging and plastics processing. Basically any repetitive task is a great fit for a robot, especially if it poses a risk to people or is difficult. The manufacturing sector is one area where robots are especially useful. Traditionally, robots have been used for high-volume tasks, but as technology develops and the cost of industrial robots comes down, more options and opportunities are opening up for medium- and small-sized businesses.

At the same time, these robots are helping manufacturers address many of the key challenges they face, including tight labor pools, global market competitiveness and safety.

Ways Robots Are Used in Manufacturing

Throughout manufacturing, robots have found niches in areas that require precision and consistency. Here are some of the areas;

1. Material Handling

Large cartons and blood samples are among the ever-expanding spectrum of materials handled by robots. Primarily materials and goods that need to be steady or hazardous goods that provide a risk of contamination when in touch with people.
Because the robots never fatigue or make mistakes while carrying out their fundamental duties, this method also lessens the possibility of endangering the lives of human workers. Robots are able to accomplish more work, requiring fewer personnel to supervise the process.

2. Welding

The application of heat and pressure to combine metal components is a risky technique that demands flawless precision. Even the smallest error on the part of the welder can cause severe harm, tarnish the metal component, and interfere with the manufacturing process.
These factors are making robots a more popular option for welding jobs. Depending on the project’s complexity, robots may complete the task alone or in conjunction with a human worker.

3. Assembling

Assembling product pieces is a tedious, time-consuming task that can be quickly derailed by a lack of concentration, boredom, and a host of other unpredictable circumstances.
A robot can take the place of such a system, greatly streamlining the procedure and lowering the chance of an error happening. This also removes the human element from the most hazardous portion of the operation, allowing them to concentrate on quality rather than quantity during the assembly phase.

4. Dispensing

Robots that dispense glue, paint, or sprays are positioned strategically along the product’s path in operations that call for applying these materials to a surface. This is just another example of a repetitive task where a robot can perform it more accurately than a human worker.

5. Workflow
Before being issued, some products need to go through a certain kind of processing, such sawing, polishing, or carving. Depending on the intricacy of the task and the robot’s capabilities, several levels of autonomy are used to complete this work by the robots.

6. Method of loading
   Manufacturing line operations involving the loading and unloading of parts are performed by robots that load and unload machinery. Manual workers may find it difficult and even unsafe to load and unload parts from a machine. Automated machine loading will increase productivity, protect your staff from injury, and remove labor-intensive, repetitive tasks.
7. Selecting, wrapping, and stacking
   Robots that are designed to choose and package products can do a multitude of functions once they are assembled. These robots pick out individual pieces fast, palletize them, and pack them properly. Because robots can choose and pack products more quickly, they can increase your production with accuracy.

8. PART TRANSFER

Heavy materials are moved throughout the structure using part transfer robots. It is risky, challenging, time-consuming, and demanding for people to carry huge, heavy pieces. Part transfer robots provide a secure way to keep employees out of dangerous situations and injury-free. You can lower labor expenses and accelerate production by integrating component transfer robots.

If you’re curious whether robots can enhance your value stream, here are the main pros and cons to consider:

ADVANTAGES OF INDUSTRIAL ROBOTS

1. Increased constancy and quality
   In conjunction with other technological advancements like 3D printing robots and the industrial internet of things (IIoT), industrial robots can offer more accurate and dependable procedures as well as higher output quality. Reduced cycle times and real-time monitoring to enhance preventative maintenance procedures are further advantages.
2. Optimal output and productivity
   Part of the reason an industrial robot speeds up manufacturing processes is that it works around the clock. Breaks and shift changes are unnecessary for robots. Throughput is maximized and cycle time is eventually decreased by the speed and dependability of robots.
3. Increased security
   When repeated jobs are performed by robots, worker injury risks are reduced. This is especially true when production takes place in harsh environments. Supervisors can also monitor the procedure remotely or online.
4. Lower direct labor expenses
   Many manufacturing tasks are more expensive to handle by a person than by a robot. Additionally, this can free up employees so they can apply their knowledge and abilities to other business domains like maintenance, engineering, and programming.
5. Maintaining American manufacturing.
   While some claim that American workers are losing their jobs to robots, this isn’t always the case. Usually, industrial robots are included into a range of tasks that need for human knowledge. For instance, a robot could weld components before being sent off to a human worker to complete an action that calls for human intuition or “if, then” reasoning.

DISADVANTAGES OF INDUSTRIAL ROBOTS

1. Expertise can be scarce Industrial robots require sophisticated operation, maintenance, and programming; while the number of people with these skills is growing, it’s still limited. As a result, it’s important to consider the personnel investment you’ll need to make to bring in that expertise or “retool” your existing staff to take on the task.
2. Ongoing costs though industrial robots may reduce some manufacturing labor costs, they do come with their own set of costs. In addition, you’ll want to consider the costs to keep your robot and any related (IIoT) connected devices protected from cyber-threats.

 BENEFITS OF ROBOTICS IN MANUFACTURING

1. HUMAN SAFETY

The most apparent benefit of using robotics is safety. Heavy equipment, hot-running machinery, and sharp things can easily hurt a person. By giving risky activities to a robot, you’re less likely to face a significant medical expense or legal trouble and more likely to face a repair bill. Robots’ ability to reduce some dangers will be appreciated by workers who do hazardous tasks.

2. SPEED

Robots don’t require breaks or are easily sidetracked. They don’t beg for a day off or depart an hour earlier. A robot can never become anxious and begin to move more slowly. Additionally, they are not required to be invited to staff meetings or training sessions. Because they can operate continuously, robots speed up manufacturing. They prevent your staff from overworking themselves to reach tight deadlines or impossibly high standards.

3. CONSISTENCY AND PERFECTION

Robots are not dependent on human labor for their work, nor do they need to divide their attention between multiple tasks. They will always be present and performing their allocated tasks; they won’t experience unanticipated emergencies or have to move to complete another urgent task. Generally speaking, automation is far more dependable than human labor.
Delivering quality will never fail a robot. They’re less prone to making mistakes since they’re designed to move precisely and repeatedly. In a certain sense, robots serve as both a quality assurance system and an employee. The absence of preferences and peculiarities, along with eliminating human mistakes, will always result in a dependably flawless product.

4. SATISFIED EMPLOYEES

Your employees are more likely to be satisfied since robots frequently handle tasks that people don’t particularly love, such as menial work, repetitive motion, or risky employment. Employees can instead focus on more complex tasks or jobs that require a human touch and creativity.

5. ABILITY TO PRODUCE
   Not everything can be done by robots. A human can only accomplish so much. If your human workers aren’t distracted by jobs that machines could do, they’ll be available and productive. In addition to assisting with branding and marketing, they can communicate with customers, reply to emails and comments on social media, and close deals. You will be surprised at how much they can accomplish when the drudge work isn’t keeping them down.

TYPES OF MANUFACTURING ROBOTS

ARTICULATED ROBOTS

A benefit of articulated industrial robots is the additional range of motion that each joint makes possible. These robots are used because of their versatility and dexterity in carrying out tasks. The rotating joints of this particular robot design range from two joint structures to at least ten joints. The arm of any industrial robot, which is its most important component, is attached to the base using a twisted joint.

ROBOTS FROM CARTESIAN SYSTEMS
This type, which is sometimes referred to as a rectilinear or gantry robot, has three linear joints that work in conjunction with the Cartesian facilitation system. This kind of industrial robot also has an additional wrist designed to support the arm’s rotational growth. A Cartesian industrial robot uses three kaleidoscopic joints to provide linear movement (along the axis). This type of industrial robot is used for sealing, stacking and exchanging tools, transport, and for other functions.

CYLINDRICAL ROBOTS

One or more hollow, spherical robots are attached at the base and operate inside a barrel-shaped area. This is because a kaleidoscope operates in a linear movement, whereas rotary joints need rotating movement.

COMMON ROBOTS
These machines are also known as spherical robots. In the case of Polar industrial robots, the arm is fixed to the base by means of a rotary joint in addition to a mix of rotary (2) and linear (1) joints. The polar coordinate system or range of motion of the industrial robot is the source of its name. They are employed in manufacturing to cut expenses associated with production, boost output, and minimize mistakes.

CONCLUSION

Robots are intended to do jobs more effectively alongside human beings to meet the demand for production in a solid and adaptable manner. Manufacturing robots can additionally deal with additional quality and sturdiness issues. Therefore, without any doubt, robots are the eventual trend in manufacturing.