Roadblocks To Implementation

The top factor we see hindering greater robot implementation is justifying the investment cost with an acceptable ROI. ROI is typically expected in two years, but some companies realize the full return in less than one year. Variables used to justify ROI include lower labor costs, higher throughput, improved quality and reduced waste, fewer worker injuries, and measurable uptime.

Other obstacles to more-widespread use include lack of internal expertise, finding the right applications, the time required for installation and training, and overcoming skepticism.

Big companies have robots in all their facilities, and probably on every line. But the fact is small and medium-sized manufacturers, to keep pace, need to supplement manual processes with targeted robotics for greater flexibility and improved output. They need to create a manufacturing environment that is automated and robotic, particularly if prices are going down.

Nonetheless, a lack of expertise is a common denominator that challenges manufacturers. As the deployment of robotics continues across the plant floor, professionals with a tailored set of skills will be needed in the future to design, integrate, and maintain a fleet of robotics.

We’ve heard in our interviews that one of the biggest obstacles for manufacturers is the perception that, “I don’t have the talent and the capability of installing robots.” It takes time, and you have to do it right, so evaluate internal talent and partner with outside experts who can help put robotics in place. As an added benefit, it would help stimulate inventiveness and embrace the digital transformation coming to manufacturing.

Identifying the root cause of production losses is a way to start. Analyze bottlenecks and identify operational improvements that will have the biggest impact. Prioritize where it would make the most sense to add a robot or to add automation.

Cobots can be an entry point. Physically smaller robotics are gaining popularity as SMEs in particular show interest in utilizing flexible, intelligent robots to enhance their manufacturing processes, provide assistance to their human employees and alleviate labor shortages. More cobot installations would be considered if cycle rates increased and users become more comfortable with the safety parameters of unguarded cobots.

The majority of survey participants predict adoption of cobots will grow. But about a quarter felt cobots would be limited to niche applications, ideal for slower applications with a lighter payload — mainly for assembly and packaging. And 22% were hesitant or unsure. More development is needed, they indicated, to ensure human safety.

And there’s still some skepticism. Do I really want to replace my workers with a robot? That can be a serious concern as many people fear robots will eliminate jobs. The fact is, more workers will be needed to run the robots.

Robotics is quickly transforming manufacturing. If you’re considering adding robots, but are unsure and put off the decision for a year or two, you might miss the window of how quickly that could have advanced your manufacturing processes, and improved your competitive standing and the bottom line.