Business magazines are full of stories about the game-changing prospects for automation, particularly robotics as labor becomes a major challenge for all industries. And it seemed that until a few years ago that the pallet industry might be left out of the robotics revolution. But a number of suppliers have developed robots to handle board feeding, component placement, pallet sortation, nailing, dismantling, materials handling functions and more.
As exciting as theses robotic developments are, you have to keep in mind that a robot is not a panacea. In some cases, other forms of automation may be better than a robot.
These considerations should guide your process as you evaluate advanced automation technologies, especially robotics. And the analysis all starts with a few key questions. What is your automation goal? Are you trying to eliminate workers? Allow for greater processing flexibility? Improve accuracy and consistency? Boost production without adding labor? There are many reasons to consider a robot.
The next major consideration is the cycle speed of the activity? Every time a robot moves back and forth you want to make sure that action is an efficient and fast as possible. Is the robot picking up or acting upon only one thing at a time? Can it do multiple actions at once, such as picking up a whole layer of boards? Can people do the activity faster?
A whole new type of robot has emerged on the scene. It is called a collaborative robot or “cobot” because it is designed to work in conjunction with human operators without security changes or other cumbersome safety precautions. These cobots are intended to share a workspace with humans and are replacing standard industrial robots in some applications.
An example of the cobot is Sawyer, a programmable robot developed by Rethink Robotics. Sawyer can maneuver in tight spaces and is trained not programmed, which makes it easier to set up. This design stands out from others because the robot has a screen that acts like a face to give visual cues to those working in the same area. Also, most cobots are designed to limit the power and force that it can apply, which can limit speed or the amount of weight that can be carried or moved.
Normal industrial robots may be faster than a cobot. But they are designed to stop production when a human enters the area. Safety cells around industrial robots can add to the footprint or require changes to the product floor layout. One consideration is federal safety rules that are still evolving when it comes to cobots. A recent article in Automation World magazine recounted a story where OSHA ruled that cobots required safety caging due to the application. Each robot deployment is different, and you may want to get an analysis from a safety expert first. Regulatory gaps can turn a good idea into a problem if you have to rethink a process.
Does the robot need to be mobile? Is it able to move back and forth on a rail? What length of reach does the robot require to do the action? Robots can also be attached to automated guided vehicles that can enhance the mobility of the system. Movement also can complicate the safety considerations. Mobile robots may require special sensors to deactivate if humans or other vehicles enter its work zone.
Most surveys conclude that robotic automation will result in the loss of millions of jobs across the developed countries within the next five years. Forrester forecasted that automation with eliminate 17% of U.S. jobs by 2027. At the same time, it will add a number of high-skilled technology jobs.
According to the Robotic Industries Association, an all-time high total of 9,773 robots valued at approximately $516 million were ordered from North American robotics companies during the first quarter of 2017. This represents growth of 32% in units over the same period in 2016. Many people believe that a tipping point in robotic deployment is imminent, especially as labor shortages plague many sectors in developed countries.
Companies have to be realistic though – robots do have limitations. While they may not get tired, can keep up consistent production and always show up for work, they do require programming and maintenance. Many companies may not have personnel who are trained to service or program robots. This is something you will have to develop or rely on vendors to provide. Many robots can do a wide variety of activities if programmed. But they can’t do a wide variety of tasks all over a plant like person can.
Robots can be awkward and slow completing some basic tasks that are easy for a human to do. Look at the towel folding video below to see how some tasks are not robot friendly. While the robot can do the task, humans can do it faster, especially when you throw variability in to the mix.
Robots are here to stay. But they might not be coming for your job right now. But with labor shortage a problem that most companies seem to be experiencing, don’t be surprised as automation takes quantum leaps forward in the next decade.
