Here’s why human-robot collaboration is the future of manufacturing

_robots_

(Credit: Unsplash)

This article is brought to you thanks to the collaboration of The European Sting with the World Economic Forum.

Author: Patrick Sobalvarro, CEO and co-founder , Veo Robotics


  • COVID-19 has highlighted the need to create more resilient supply chains and the importance of human workers.
  • Automation alone can be expensive and inflexible, because robots are typically designed to carry out just one precise task.
  • The best choice is to pair robots with human workers, combining the strength and speed of industrial robots with the creativity and ingenuity of humans.

The COVID-19 pandemic has dealt a heavy blow to manufacturers around the world. Lockdowns and travel bans have disrupted production as well as supply chains. New outbreaks in factories and other workspaces have highlighted the need to better protect workers’ health and safety. In a March 2020 survey by the National Association of Manufacturers (NAM), 53% of manufacturers anticipated a change in operations due to COVID-19.

This need for transformation goes beyond the immediate coronavirus crisis. The manufacturing industry is under pressure to respond to ever-changing market needs. Modern demands of mass customization, higher product variability and quality expectations, and faster product cycles are creating complex challenges for manufacturers, whose economics are best suited to much longer product cycles and limited variability.

If manufacturers want to compete in a fast-evolving global market, they will need to fundamentally transform the way they produce goods. Now is the time to tackle these long-standing challenges by pairing human skill and creativity with the strength and speed of robots.

manufacturing, production, coronavirus, pandemic,

What is the World Economic Forum doing to help the manufacturing industry rebound from COVID-19?

The COVID-19 global pandemic continues to disrupt manufacturing and supply chains, with severe consequences for society, businesses, consumers and the global economy.

As the effects of coronavirus unfold, companies are asking what short-term actions they need to take to ensure business continuity and protect their employees. How should they be preparing for the rebound and increasing their manufacturing and supply systems’ resilience?

The World Economic Forum, in collaboration with Kearney, brought together senior-level executives from various industry sectors to identify the best response to the COVID-19 crisis. Their recommendations have been published in a new white paper: How to rebound stronger from COVID-19: Resilience in manufacturing and supply systems.

 

Read the full white paper, and more information in our Impact Story.

Companies are invited to join the Forum’s Platform for Shaping the Future of Advanced Manufacturing and Production. Through the Platform’s work, companies can join with other leaders to help find solutions that support the reconfiguration of global value chains post-COVID-19.

The challenges of automation

Today’s industrial robots maneuver heavy and dangerous workpieces at high speeds, and cannot safely operate near humans. That’s why most manufacturing process steps are either fully automated or fully manual. However, this black-or-white approach to automation introduces new problems.

One is that automation is expensive and time-consuming to design. The precision robots enable is a double-edged sword—each process step requires specific coding and relies on uniform and predictable parts and tools. If anything is slightly off, the machine cannot function correctly and the production line must be stopped. Due to these inefficiencies, excessive automation can increase costs and lengthen production schedules.

On the other hand, relying solely on human workers to handle large, unwieldy parts can make their work straining, slow-moving, and dangerous. Constant, repetitive motions can lead to repetitive stress injuries. Additionally, exhausted and uncomfortable workers are more liable to make mistakes, decreasing quality and productivity.

Working together

The idea of a fully automated “lights-out factory” with no production workers—one requiring only machine programming and maintenance—has proven to be a dead end. So much of what happens in a factory requires human ingenuity, learning, and adaptability. As products have become more varied and customized to local markets and customer needs, the economics of full automation make no sense. The immense engineering costs and time required to bring up a fully automated line for a complex product can never be amortized before the product needs to be changed.

The best choice is to combine the strength, precision, and speed of industrial robots with the ingenuity, judgment, and dexterity of human workers. This way, human workers can take on tasks that require flexibility, while the robots handle tasks that make the best use of their strength and speed.

Image: Kaiser L., Schlotzhauer A., Brandstötter M. (2018) Safety-Related Risks and Opportunities of Key Design-Aspects for Industrial Human-Robot Collaboration. In: Ronzhin A., Rigoll G., Meshcheryakov R. (eds) Interactive Collaborative Robotics. ICR 2018

Manufacturing processes are faster, more efficient, and more cost-effective when humans and robots work together. In a study conducted by MIT’s Julie Shah, idle time is reduced by 85% when people work collaboratively with a human-aware robot compared to when working in all-human teams. Our own work at Veo finds that the cycle time for a simple assembly task can be roughly halved using human-robot collaboration as opposed to only humans. In a case study of solutions for packing boxes onto pallets conducted with Advanced Robotics for Manufacturing (ARM), we found that a collaborative approach cuts cycle time by almost two-thirds compared to a fully manual approach.

Additionally, while excessive and rigid automation today makes retooling an onerous and lengthy process, the flexibility of human-robot collaboration allows manufacturers to easily adapt to shifting demand with new products and processes. In our palletizing case study, we find that the fully automated process can take days or even weeks to reprogram and fit with additional fixturing—this downtime is costly. The collaborative approach benefits from the inherent adaptability of human workers, and only requires a day or perhaps a few days for some reprogramming of the palletizing robot arm.

 

Changes ahead

The advantages of robot-human collaboration were already known before the COVID-19 pandemic, but the crisis has made it even more necessary to join forces. Factories that are flexible enough to keep up with market demands could have the ability to quickly pivot from producing automotive components to medical equipment and back again. Factories that don’t have this flexibility as part of their design would struggle with such rapid change.

What’s more, as manufacturers begin to reopen their facilities, they will need to implement safe social distancing practices. Processes built for human-machine collaboration will be a major advantage. For example, a process step that involved two or more production workers working closely together may be split into multiple process steps, or it may turn into a process step that involves one worker and one robot.

We will likely also see more supply diversification. Instead of sourcing a component from a single supplier, a manufacturer may instead solicit smaller orders from a variety of suppliers in different locations to mitigate potential supply chain shocks (like those seen in March as the pandemic moved across Asia). These new lines will each have shorter runs of particular components. It makes little sense to design and implement expensive, fully automated systems for such short runs. Instead, the solution is to employ human workers and use automation efficiently.

Manufacturers can use this as an opportunity to reevaluate their production processes. Now that enabling technologies for safe human-robot collaboration are becoming widely available, it’s the perfect time to restructure factories around collaborative automation that helps keep workers safe and improve factory economics. Many auto and durable goods manufacturers are already taking steps to incorporate systems for safe collaboration, such as Veo FreeMove. Now it’s time for the rest of the manufacturing industry to follow suit.

Some imperatives remain clear: the improvement of living standards and the improvement of working conditions are crucial. As the pandemic has shown, advancements such as modern medical devices depend on increased productivity in manufacturing and continued advances in the quality, availability, and suitability of manufactured goods. This can be accomplished together with improved safety and ergonomics for production workers by making machines aware of and responsive to the presence of workers around them.

the sting Milestone

Featured Stings

Can we feed everyone without unleashing disaster? Read on

These campaigners want to give a quarter of the UK back to nature

How to build a more resilient and inclusive global system

Stopping antimicrobial resistance would cost just USD 2 per person a year

Qualcomm to be the next target of EU antitrust regulators? China might be the answer

France breaks budget promises once again and the EU’s finance offices are shaking

COVID-19 shows why we must build trust in digital financial services

Amazon: our green is turning to ashes

EP President praises Nobel Peace Prize award to Denis Mukwege and Nadia Murad

Suriname’s climate promise, for a sustainable future

Medical students: catalysts to close the gender gap

As people return to work, here’s how we can make commuting more inclusive and sustainable

Safety fits into our palms: The role of mobile technology in healthcare systems and life saving

Keep Africa’s guns ‘from firing in the first place’, UN political chief urges

Algorithmic warfare is coming. Humans must retain control

Paris, Rome, Brussels and Frankfurt to confront Berlin over growth and the Athens enigma

How the institutional response to COVID-19 can prepare us for climate change

Germany is turning its old mines into tourist hotspots

Turkey’s Erdogan provokes the US and the EU by serving jihadists and trading on refugees

Yemen bus attack just the latest outrage against civilians: UN agencies

We need to protect 30% of the planet by 2030. This is how we can do it

Friday’s Daily Brief: UN chief in China, counter-terrorism, updates from Bangladesh, Mali and Mozambique

7 steps to becoming a ‘CEO Academy’

Merkel refuses to consider the North-South schism of Eurozone

Coronavirus: Commission adopts new exceptional support measures for the wine sector

MEPs vote for upgrade to rail passenger rights

Juncker and Tusk killed Greece on 07 July 2015 to meet the Commission’s summer vacation plan? #Grexit #Greferendum #Graccident

‘Protracted crisis’ in Venezuela leads to ‘alarming escalation of tensions’: UN political chief

Afghanistan: Civilian casualties exceed 10,000 for sixth straight year

A letter from Italy: Our insecurity in COVID-19 times

These coastal countries are sinking the fastest

Women still struggle to find a job, let alone reach the top: new UN report calls for ‘quantum leap’

‘Act now with ambition and urgency’ to tackle the world’s ‘grave climate emergency’, UN chief urges UAE meeting

European Commission statement on the adoption of the new energy lending policy of the European Investment Bank Group

A challenge for inclusion in the Dominican Republic’s health care services

There is no recipe for a healthy mental state

Outbreaks and pandemics periods can be stressful, but how can we turn it to a positive life-changing experience?

International World Summit Award calls for outstanding digital applications with impact on society from 178 UN member states

China greenlights first underwater high-speed railway

Three out of the past five Julys were the hottest on record

COP21 Breaking News_04 December: Commitments Made to Reduce Black Carbon, Methane and HFCs

Medical workforce migration in Europe – Is it really a problem?

Investing in rural women and girls, ‘essential’ for everyone’s future: UN chief

European Parliament speaks out against “killer robots”

10 million Yemenis ‘one step away from famine’, UN food relief agency calls for ‘unhindered access’ to frontline regions

These are India’s cleanest cities

EU Border and Coast Guard: new corps of 10 000 border and coast guards by 2027

7 lessons leaders should take from the COVID-19 crisis

We won’t win the online security war without people power

The world is a book and those who do not travel read only one page

Q&A on extraordinary remote participation procedure

EU Elections: new rules to prevent breaches of data used to influence elections

Mining the deep seabed will harm biodiversity. We need to talk about it

Congolese expelled from Angola returning to ‘desperate situation’: UN refugee agency

In West Africa, UN Security Council visits Côte d’Ivoire and Guinea-Bissau

JADE President opens JADE Spring Meeting 2014

Commission welcomes the political agreement on the transitional rules for the Common Agricultural Policy (CAP)

Cameroon: Clear ‘window of opportunity’ to solve crises rooted in violence – Bachelet

The EU Commission fails to draw the right conclusions about corruption

How youth and technology can drive Africa’s COVID-19 response

We are ‘burning up our future’, UN’s Bachelet tells Human Rights Council

How to change the world at Davos

5 ways to get your business ready for AI in 2020

UN, global health agencies sound alarm on drug-resistant infections; new recommendations to reduce ‘staggering number’ of future deaths

More Stings?

Advertising

Speak your Mind Here

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Google photo

You are commenting using your Google account. Log Out /  Change )

Twitter picture

You are commenting using your Twitter account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s