Advanced Manufacturing: Collaborative Robots (Cobots)

The evolution of manufacturing has brought a higher level of technology and skillsets in demand. PBC Linear is continuing to build upon previous successes in lean manufacturing by implementing new automation technologies and upscaling its workforce. These automated technologies provide the advantage of completing tasks that were considered monotonous, labor-intensive, and posed a higher risk of injury for personnel. The human advantage is a transfer from these laborious tasks to more elevated skillsets that include a heightened focus on the inspection process and the quality of parts. The result for PBC Linear is a factory that is leaner, smarter, safer, and capable of greater output.

This article and the video below are part of a longer series that details how PBC Linear is incorporating technological enhancements into its production systems. The following content offers an introduction to collaborative robots, the insights gained during their implementation, and the resulting benefits to our workforce, business, and most importantly our customers.

Cobots and teamwork

Cobots are collaborative robots. Both the name and the description reflect their ability to work side-by-side with the human workforce to safely achieve greater output efficiency and quality. The cobot fulfills its role by utilizing these fundamental advantages:

  • Built-in sensors that interact with servo motors, making them extremely safe and user-friendly. For example, if there is a force limit that is exceeded by bumping into an operator or other object, the cobot will sense this, stop, and then require a reset to restart the operation.
  • Higher efficiency in repetitive labor such as pick and place, resulting in higher product output.
  • Ease of performance of previously hazardous tasks, where risk of injury exists from heavy lifting or running machines.

These cobot strengths also allow workers to be reestablished into higher skilled roles. Now, the technician that had previously mastered this work will instead be monitoring the cobot, or multiple cobots, while simultaneously checking for quality, providing processing feedback, and making fine-tuned adjustments.

Image for Manual vs Automated Methods
Tim, the Director of Manufacturing, offers his views on Manufacturing

Tim L., Director of Manufacturing

A cobot is an excellent assistant that can aid the team by taking over the basic functions of loading and unloading the machine. However, it is limited in its ability to discern whether a part is good or bad, making it just an extension of the machine. This allows us to train the operator to focus more on the quality of the parts.
Cobot working collaboratively with Workforce

Cobots and the labor force

As we continue to move further into this decade, it has become evident that the entire manufacturing sector is dealing with a shortage of skilled labor. Some factors for this shortfall include lack of promotion within high schools and higher education, and the simultaneous retiring of older, skilled workers. The result of these outside forces has produced a gap of qualified personnel that businesses are struggling to fill. As one solution, the cobot brings the potential to satisfy some of those existing labor needs.

In addition, when PBC Linear brings on a new hire, there is a steep learning curve that involves training on both the running of the equipment and the inspection of parts. It’s a lot to learn at once, but by applying the assistance of the cobot to take over some of the basic functions, we can now focus operator training on quality and inspection.

Meet the Cobots

The first impression of our cobots can be described as sleek, shiny and clean. They have six joints for smooth motion, allowing them to twist and turn to fit many different task configurations. Unlike some other comparable machines, our cobots have a set of control buttons on the tool end affector that allows operators to teach a point by simply pressing a button and then moving the cobot to the desired position. All of this can be done without a bulky pendant, allowing for more control during the programming stage.

Cobots in pick and place application
Engineers can also program more sophisticated functions, like executing an open and close door function, or even write a macro for the cobot. For example, we can program the cobot to put every tenth part in an inspection station. Once a part is in the inspection station, we can then program a pass or fail option where, if a part is marked as fail, the cobot will automatically pause to wait for an operator to make an adjustment.

The value of cobots

For years, PBC Linear had considered installing robots. Unfortunately, pricing, plus safety factors such as barrier fencing and door interlocks, made it far more costly that any labor-saving benefits from industrial robots. More recently, the company owners have had the opportunity to witness a few of these cobots in action. After careful analysis, they realized the automation potential and affordability of these machines. In fact, the price-point of a cobot generally results in very short return on investment.

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Tim L., Director of Manufacturing, offers advice on the economics of cobots

Tim L., Director of Manufacturing

Cobots will be a necessity to stay in business within this economy. Imagination is the only limit. So far, we have not found a manual operation that cannot be programmed and performed by our cobots.
Beau W., Mechanical Engineer and Cobot Project Manager

Beau W., Mechanical Engineer, Cobot Project Manager 

The bottom line is increased production. Collaborative robots contribute to a significant increase in the number of cycles we can run, as well as the time of day when we can run those cycles.

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See more on how PBC Linear is bringing automation and higher output to its manufacturing processes: