How Collaborative Robots Can Speed Up Small Batch Orders

Cobots, or collaborative robots, have recently changed the industrial sector. Cobots are industrial robots that are made to operate alongside human operators safely and cooperatively. This is in contrast to traditional industrial robots, which are frequently big, expensive, and need high programming and maintenance skills. Because of this, they are perfect for small-batch orders where adaptability and agility are essential.

What Are Collaborative Robots?

Collaborative robots can work safely alongside human operators without the need for safety barriers or other protective devices. Compared to conventional industrial robots, they are often smaller and more versatile and designed to be simple to control and program.

Collaborative robots are excellent for small-batch orders where manufacturing needs might change quickly since they can be reconfigured to execute a wide range of jobs. It does not require costly retooling or reprogramming, so that it can save time and money.

What Sets Cobots Apart from Conventional Robots?

Industrial robots used nowadays are often giant, heavy devices made to carry out particular jobs precisely and repeatedly. They are frequently employed in large-scale production processes where accuracy and speed are crucial. These robots need specific programming and upkeep, and they are typically kept apart from human employees by physical barriers or safety fences.

Collaborative robots, on the other hand, are intended to work with humans in a shared office. They are easier to handle and program than traditional robots, smaller, and more adaptable. Cobots may operate securely alongside human employees without physical boundaries because they are outfitted with cutting-edge sensors and safety features that enable them to recognize and react to human presence.

Collaborative robots can accomplish activities like assembly and quality control that involve human skill and judgment, which is one of their key benefits. They are perfect for small-batch manufacturing and flexible production environments because they can be swiftly reprogrammed and redeployed for varied activities.

Cobots’ accessibility and cost are further benefits. Cobots are meant to be simple to program and operate with intuitive user interfaces that allow non-experts to set up and run them, unlike traditional industrial robots that may be costly and require specialized training and maintenance.

The Rise of Small Batch Orders

Small-batch orders are increasingly common in manufacturing, which can be attributable to several variables. The rising demand for customization and personalization in consumer goods is one of the primary drivers of this trend. Small-batch orders enable producers to satisfy consumers’ growing need for items that are customized to their unique requirements and tastes.

The advent of modern manufacturing technologies like 3D printing, which make it simpler and more affordable to create small quantities of goods, is another factor influencing the development of small batch orders. Small firms and entrepreneurs now have lower entry barriers since they can make their goods in small quantities without significant expenditures in manufacturing equipment.

In addition, the expansion of e-commerce and online marketplaces has made it simpler for producers to reach specialized markets and do direct business with customers. As a result, producers may now make small quantities of niche goods and sell them directly to customers via Internet channels, opening up the potential for small-batch production. In general, the increase of small batch orders in manufacturing is fueled by customer desire for personalization, improvements in production technology, and the expanding usability of online markets. We can anticipate more small enterprises and entrepreneurs joining the manufacturing sector and more customers taking advantage of individualized and customized items as this trend advances.

Collaborative Robots’ Workflow

In small batch orders, collaborative robot workflow generally consists of the following steps:

• Programming: Cobots are programmed to carry out particular activities using a software interface. Either the machinist or an automation engineer can perform the programming.
• Integration: Cobots are included in the manufacturing process by employing sensors and other devices to connect them to the machines or other equipment.
• Cobots are checked to ensure they carry out the jobs precisely and effectively.
• Cobots are put into use when testing is finished to assist machinists.

Cobots Can Operate in Various Settings, Including:

Material handling: By handling materials and parts, collaborative robots free up machinists to work on more complex jobs.

Collaboration robots can be utilized for machine tending duties like loading, unloading, and freeing machinists to focus on other projects.

Collaboration robots can be used for inspection to ensure that parts and products meet quality control requirements. This can allow machinists to focus on other activities while still upholding quality requirements.

Collaboration robots can assemble components and finished goods, eliminating the need for manual labor while increasing productivity.

Collaboration robots can do welding operations, which lowers the possibility of mishaps.

How Cobots Can Make an Impact and Speed Up Small-Batch Orders

• Improved safety: Collaborative robots are designed to work alongside human operators safely and collaboratively, reducing the risk of accidents and injuries.
• Increased efficiency: Collaborative robots can handle repetitive or mundane tasks, allowing machinists to focus on more complex tasks. This can improve overall efficiency and reduce the risk of errors.
• Collaborative robots help small businesses manufacture on a small scale to grow and compete with larger organizations because they are an additional helping hand for the mechanists.
• Reduced worker fatigue and injury risk: In various industries, we come across many processes which involve the risk of injury and hazard, which could lead to the inefficiency and completion of the task. Many industries involve packaging and assembling parts of fragile material (brittle metals), which could lead to worker fatigue.
• Improved product quality and consistency: Collaborative robots can speed up the process because we can set their parameters for carrying out tasks long-term. Making a specific product in bulk requires the same quality and outlook. Hence, it provides consistent symmetry to all the order material.
• Faster turn-around time for manufacturing orders: Similar orders vary in turn-around time when completed by humans compared to collaborative robots. Humans need breaks during their work hours, contrary to which collaborative robots can work endlessly and prepare the same order in a limited amount of time without stopping.  
• Increased Flexibility: Let’s suppose that the worker was working on a specific batch order, and then suddenly, instant instructions are received by higher authority to shift their attention to some other type of assembly and manufacturing. This can be tiring as far as the mechanist is concerned because s/he worked with a specific mindset on a particular task which now becomes a previous task due to a new task infused by the higher authority. Collaborative robots can solve this flexibility issue because, when programmed, they can swiftly change the task and will start working on a new task.
• Reducing wastage during the process: Workers confronting some batch orders are more likely to waste certain materials due to their loss of focus. One can only work with 100% efficiency some of the time, so this waste can be lessened by using collaborative robots.
• A complementary workforce: Two working hands are far better than one. This is the same case with collaborative robots, which serve as additional help for the mechanist and make his life a bit easier.    
• Optimized Resource Utilization: Collaborative robots, when programmed, know that the resources are minimum and there is no room for waste and mistakes. That’s why they can help in budgeting the batch manufacturing cost when used alongside the mechanist.
• Improved Working Conditions and Job Satisfaction for Machinists: These robots make the life of mechanist easy. They know that they can be assisted with a technology that rarely makes mistakes in its duty when programmed properly. In this situation, the mechanist knows that there is very less chance of fault occurrence; hence they feel secure about their job.
• Increased accuracy: Collaborative robots are highly accurate and can perform tasks with a high degree of precision. This can be particularly important for small batch orders where quality control is critical.
• Cost savings: Collaborative robots are typically less expensive than traditional industrial robots and can be quickly reprogrammed to perform a wide range of tasks. This can save businesses money by eliminating the need for expensive retooling or reprogramming.
• Increased Competitiveness and Market Position: Cobots are specifically famous for speeding up and covering mass orders in a limited amount of time. The main aim of any company is to deliver high-quality products at the right time to the right people, so when a company is on the right track, then they get maximum orders for that product, and their market position becomes stronger than before.
• Enhanced Data Collection and Analysis for Continuous Improvement: Cobots use artificial intelligence and complex neural networks to memorize the pattern they used to work in. Once trained, they can perform the same task repeatedly with maximum effectiveness. They can collect and analyze data in real time, providing valuable insights into machine performance, quality metrics, and production efficiency.
• Handling Customized orders: Sometimes, there can be orders with specific demands and designs, and in a fast-paced environment like ours, they need to be addressed quickly. Carrying out customer demand becomes easy when we use cobots because they are designed and well-equipped to perform in specific conditions.  
• Production Capacity: More products can be furnished in a said amount of time which will not only increase sales but also saves time and complexity for the mechanist.

The Best Practices for Successful Implementation of Collaborative Robots in Small Batch Orders

• Identify the Right Applications: It is important to identify the right applications for cobots in small-batch order manufacturing. Cobots are best suited for repetitive and low-value tasks that require human supervision. Identify areas where cobots can add value by increasing productivity, efficiency, and flexibility, and then assign them work according to it. 
• Evaluate Safety Risks: Collaborative robots are designed to work safely alongside humans, but it is important to evaluate the safety risks associated with their use in small-batch order manufacturing. Identify potential hazards such as sharp tools, heavy parts, and moving machinery, and implement appropriate safety measures such as barriers, sensors, and emergency stop buttons.
• Plan for Integration: Collaborative robots need to be integrated with existing equipment and software systems in small-batch order manufacturing. Plan for integration by identifying compatibility issues, communication protocols, and software requirements. Work with vendors and suppliers to ensure seamless integration.
• Train and Educate Employees: Collaborative robots require specialized training and education for successful operation and maintenance. Train employees on how to operate, program, and maintain cobots safely and efficiently. Provide ongoing education and support to ensure employees are up-to-date with the latest technology and best practices.
• Start Small and Scale Up: Start small by implementing cobots in areas with the highest potential for improvement. Evaluate the results and scale up gradually by adding more cobots as needed. This allows for incremental improvements and reduces the risk of failure.
• Maintain and Upgrade Equipment: Collaborative robots require regular maintenance and upgrades to ensure optimal performance and longevity. Implement a maintenance schedule and upgrade plan to ensure that cobots are operating at peak efficiency.

Nonetheless, despite their advantages, collaborative robots still encounter a number of challenges when manufacturing small-batch orders:

• Reduced Payload Capacity: Because cobots are intended to operate alongside people, they have a lesser payload capacity than conventional industrial robots. Their capacity to handle heavy components or tools needed for small-batch orders may be constrained by this.
• Reduced Reach and Range of Motion: As compared to conventional industrial robots, cobots have a smaller reach and range of motion. This may affect their capacity to carry out intricate or precise operations needed for small batch orders.
• Restricted Speed: Cobots normally operate at a lesser pace than conventional industrial robots, which might reduce their productivity in situations involving small batch orders when speed is essential.
• Integration with Existing Equipment: Due to discrepancies in communication protocols and software platforms, integrating cobots with existing equipment in small batch order production might be difficult.
• Programming cobots may be challenging, particularly for small-batch orders that call for frequent switchovers and adjustments.
• Safety Compliance: It might be difficult to ensure that cobots adhere to safety rules and laws when operating in small batches with human operators or in dynamic conditions.
• Cost: Cobots can be pricey, especially when used for small-batch orders where the ROI might not be strong or fast.
• Lack of Knowledge: Small batch order producers might not have the skills and knowledge necessary to operate and maintain cobots, which might result in underuse or even accidents. Cobots need human input to complete jobs, which might reduce their autonomy and effectiveness in small batch orders.
• Environmental Aspects: Cobot’s performance in small batch orders may be impacted by environmental aspects such as temperature, humidity, and vibration.

The Future of Machinists and Cobots in Small Batch Orders

• Increasing Collaboration: In small batch order production, collaborative robots, and machinists will continue to collaborate, with cobots doing repetitive and low-value jobs and machinists concentrating on higher-value tasks that call for human knowledge and creativity.
• Increased Flexibility: Cobots will be able to execute a greater range of jobs and interact with a wider range of tools and software systems as they become more adaptive and versatile. Small-batch order producers will be able to respond to client requests, and market changes more quickly as a result.
• Improved Safety: It will become increasingly safer for collaborative robots to work alongside machinists in small-batch order manufacturing as they continue to incorporate safety measures. The likelihood of workplace accidents and injuries would be reduced as a result, and employee confidence and satisfaction would increase.
• Advancements in artificial intelligence (AI) and machine learning (ML): As AI and ML progress, cobots will grow smarter and better at teaching themselves, enabling them to adjust to changing business conditions and perform real-time process improvement.
• Greater Customization: As the market for personalized goods expands, cobots will be better able to create highly customized, one-of-a-kind products in small numbers. Small-batch order manufacturers will be better able to distinguish themselves from the competition and provide customers with greater value as a consequence.
• Collaborating remotely: In today’s world, we are experiencing an increase in remote work and virtual collaborations allowing small-batch order manufacturers to tap into a global talent pool and expand their capabilities.

This entry was posted on May 31st, 2023 and is filed under Uncategorized. Both comments and pings are currently closed.