Integration of a cobot into a production line in manufacturing industries - step by step

Estimated reading time: approx. 8 minutes

TL;DR

• Cobots are collaborative robots designed to work safely side-by-side with humans.
• Integration of the cobot includes process analysis, model selection, bench design and exact configuration.
• Implementation allows increase productivity and relieve operators of monotonous or heavy tasks.
• Keep safety standards and carry out a risk assessment (ISO 10218, ISO/TS 15066).
• Specialist support speeds up the process and prevents errors at the design and commissioning stages.

Table of contents

- Introduction
- Why are manufacturing industries betting on cobots?
- Key steps for integrating the cobot into the production line
- Practical tips for manufacturing industries - how to avoid mistakes
- Integration of a cobot into an existing production line - a short example study
- Does it pay to integrate a cobot in every manufacturing sector?
- Support from integration specialists - the key to success
- Safety and regulations - the most important standards
- Challenges in integration and how to solve them
- Key benefits of cobot implementation for manufacturing industries
- Recommendations and practical conclusions
- Summary
- FAQ

Introduction

Manufacturing industries are increasingly turning to robotic solutions to improve process efficiency and optimise costs. One of the most interesting trends in this area is the integration of cobots, or collaborative robots, into existing production lines. Unlike traditional, fenced-off industrial robots, cobots can safely work side-by-side with humans. This guarantees greater flexibility and reduced production cycle times. If you are wondering what benefits you can gain from implementing cobots and how to go about the integration yourself, this article offers practical tips and proven methods.

In this text, we will explain step-by-step the process of setting up a cobot and how to ensure smooth collaboration between the machine and the workers. We will also bring you up to speed on safety issues and tell you about the opportunities offered by cooperation with Michale Automatika, the official distributor of SIASUN robots and an experienced integrator in the field of machine and production line construction. After reading, you will learn how to prepare your plant for the first cobot tests and what to look out for in daily operation.

Why are manufacturing industries betting on cobots?

Manufacturing industries face many challenges, such as:

• High labour costs in the face of staff shortages.
• The need to maintain high quality with high order variability.
• Pressure for faster turnaround and short delivery times.

Cobots, or collaborative robots designed to operate safely in the presence of humans, fit in with these needs. Their implementation makes it possible:

• Increased production flexibility - easily rearmed and transferred to other tasks.
• Relieving people of monotonous or aggravating tasks such as packing or loading.
• Maintain high safety standards with advanced contact detection systems.
• Ability to work with existing machinery with minimal changes to infrastructure.

The investment costs for cobots are generally lower than those for large industrial robots, and the return on investment (ROI) time can be extremely attractive. As a result, companies in industries ranging from food to metal are increasingly bold in introducing collaborative robots into their production halls.

Key steps for integrating the cobot into the production line

In practice, integrating a cobot into a production line requires good organisation and careful planning. Below, we outline the key steps that should precede the launch of the first automated station.

1. Process analysis and identification of needs

The first step is to assess where in the production process a cobot can bring the most benefit. Repetitive tasks (e.g. component stacking, assembly of small components), potentially hazardous tasks or tasks that require a group of operators are natural starting points. At this stage, it is worth assessing not only the current but also the future needs of the plant to ensure that the investment will be scalable in the long term.

2. choosing the right cobot model

There are a number of cobot manufacturers on the market - in addition to traditional industrial robots. The key parameters are primarily:

• Load capacity.
• Arm working range.
• Number of axles.
• Expandable with additional tools (e.g. grippers, vision measurement systems).

An example of a versatile device in this segment is the SIASUN SR25A-12-2-01 robot (see description in the Products section of the Michale Automation website), which can be adapted to a variety of tasks within a single production line. When also looking for other robots with similar capabilities, pay attention to the level of safety and ease of programming.

3. stand design and safety assessment

Cobots make it possible to partially dispense with fencing off machines with special partitions, but still require a risk assessment to be carried out and safety standards to be taken into account (especially ISO 10218 and ISO/TS 15066). This makes it possible to set operating parameters, such as the maximum speed of movement or permissible lifting capacity, so as to ensure full operational safety for both man and machine.

From a design perspective, it is most important to define the cobot's work zone to avoid collisions with other equipment and personnel. It is also worth considering ergonomics: in which position the worker will pick up the semi-finished products and whether access to the cobot controls is intuitive.

4. Software installation and configuration

The configuration of the cobot includes, among other things, the connection of input and output interfaces (so-called I/O), as well as integration with the line control system. The cobot needs to know when it should pick up a workpiece from the conveyor and pass it on to the next operation. This is followed by calibration - adjusting the settings to the specific requirements of the task and checking that the grippers and sensors respond correctly to movements in the space.

Practical tips for manufacturing industries - how to avoid mistakes

In order for the integration to run smoothly and produce the desired results, several organisational and technical issues need to be addressed.

Ensure job flexibility

Unlike stationary industrial robots, cobots are often used for different tasks within a single production area. If you need robotic packaging at the moment, but are planning to implement automated grinding in a few weeks' time, it is worth anticipating this change already in the bench design. A well-designed space and modular solutions (e.g. work tables on wheels, easy-to-change grippers) will allow the cobot to move seamlessly when a new task arises.

If you're wondering which processes are best robotised in the first place, you'll find useful information in Michale Automation's range of Robotisation of packaging or Robotisation of grinding. These are examples of off-the-shelf solutions that can be adapted to the conditions of many industrial plants.

Remember to train your employees

Cobots are intended to be user-friendly machines. However, basic training of the crew in safe operation and the simplest changes to the programme is still needed. Such training also has the positive effect of increasing motivation - operators will feel their work gaining new perspectives and begin to understand how the cobot relieves them of monotonous or heavy tasks.

Implement tests and measure results

During the first start-ups, test different variations of the cobot's operation. Check that the speed parameters in specific movement phases translate into optimal performance. Analyse data from sensors and loggers (e.g. cycle time, number of parts processed) to continuously improve the process. If you want to confirm the cost-effectiveness of your implementation, you can base your ROI calculation on the indicators you find in the ROI calculator provided by Michale Automation. Although it applies primarily to welding, the method of counting can also be transferred to other robotic processes.

Integration of a cobot into an existing production line - a short example study

An example is a company in the food sector that decided to automate the palletisation process of finished packages. After an analysis, it was noticed that workers were stacking thousands of boxes on wooden pallets every day and often complained of back pains related to the long, repetitive work.

• Task: automatic stacking of packages on pallets.
• Solution: introduction of a cobot with a load capacity of up to 10 kg, equipped with a universal gripper for picking up cartons.
• Implementation stages:
  1. Determination of the dimensions of the packaging and the height of the individual layers on the pallet.
  2. Designing a modular stand that can be easily relocated close to the new conveyor belt.
  3. Calibration and safety testing to minimise the risk of squashed parcels and ensure smooth human interaction.
• Effects: a clear reduction in the duration of paving operations, a reduction in worker injury and an increase in productivity of several per cent.

Thanks to such an implementation, the food company was able to streamline work in the final stage of production by redeploying some of the staff to more complex tasks related to quality control and the preparation of shipping documentation.

Does it pay to integrate a cobot in every manufacturing sector?

Not all manufacturing industries will benefit equally from the implementation of a cobot. For example, if the main concern is the need to transport very heavy loads (over 100 kg), a traditional industrial robot with a heavy lifting capacity is still a better choice. On the other hand, many industries such as food, cosmetics, pharmaceuticals or electronics will thrive on collaborative technologies with a cooperative robot:

• Packaging and sorting processes for small parts.
• Soldering and assembly of electronic components.
• Packaging tasks, e.g. putting bottles back on the belt.
• Ancillary work where delicacy or precision of movement is important.

With automated systems in the metal or automotive industry, where high production speeds and the need for high lifting capacity are present, the cobot can be a good addition in those areas where frequent operator passes or precise quality control is required.

Support from integration specialists - the key to success

Implementing a cobot does not have to be a complicated process, but it does require knowledge of industrial automation, mechanics and health and safety regulations. Companies such as Michale Automatika offer a comprehensive service, starting with a process audit, workstation design and robot selection, through to service and maintenance. With a professional approach, you can avoid mistakes that would cost you downtime or additional upgrades.

Safety and regulations - the most important standards

Cobots operate in an environment where humans are present, so safety is a priority. The most relevant legal obligations relate to:

• Risk assessment and hazard reduction in accordance with EN ISO 10218-1 and 10218-2, which provide guidance for robot manufacturers and users.
• Adherence to the requirements of ISO/TS 15066, which describes the limit of human-robot contact zones.
• Ensure that each employee has been trained in the use and safe interaction with the cobot.

This type of work is best outsourced to specialists who are experienced in conducting safety tests and know how to properly limit the cobot's movement parameters to minimise the risk of accidents.

Challenges in integration and how to solve them

Although cobots are relatively easy to set up, there can still be problems at the integration stage:

Lack of adequate space around the line

This happens especially in older halls where legacy machines are set up tightly. It is good practice to reorganise the production layout so that the cobot has a designated working area and is easy to rearrange if necessary.

Changing the mindset of employees

In some plants, there is a fear among people that robots will replace their jobs. Explaining the real objectives of implementation - to relieve repetitive tasks and improve safety - often elicits understanding and acceptance from staff.

Integration into a legacy control system

Additional communication gateways, controller upgrades or PLC software updates are sometimes needed to ensure smooth communication between the new cobot and existing line elements. It is worth thinking about this already when planning the investment.

Key benefits of cobot implementation for manufacturing industries

• Increase process efficiency and stability.
• Improved ergonomics and worker safety (fewer injuries and accidents).
• Flexibility - the ability to quickly redeploy the cobot to another operation or another part of the shop floor.
• Ability to design mobile workstations and make temporary improvements to production.
• Easy extension with additional functions, e.g. video object recognition, which reduces set-up and changeover times.

Recommendations and practical conclusions

• Carefully analyse your plant's processes to identify the stages where a cobot will bring the fastest return on investment.
• When pricing and estimating ROI, also take into account 'soft' factors, i.e. reduced risk of injury and increased comfort.
• Invest in operator and manager training so that they understand how to programme and carry out basic cobot maintenance.
• Choose modular solutions and accessories that work well for different operations (handling different details, operating several stations).
• If you lack knowledge or resources, enlist the help of experienced integrators. External support at the design stage will help you avoid costly mistakes and downtime.

Summary

Integrating a cobot into a production line is an opportunity to improve efficiency, flexibility and safety in many manufacturing industries. With the ability to work side-by-side with an operator and quickly adapt to new tasks, cobots are becoming the answer to the needs of both large and smaller companies.

A well-conducted analysis, careful station design and attention to safety and employee training are key to a successful implementation. When in doubt, it is advisable to seek advice from companies such as Michale Automation, which will help to select the optimal solutions and configure robotic workstations for specific production conditions.

If you are looking for inspiration on how to automate more areas in your plant, take a look at the Robotisation and check out the proposed solutions. Consider whether integrating a cobot into peripheral production processes (e.g. packaging or preparation of semi-finished products) will accelerate your company's growth.

We also encourage you to comment on the article and ask questions. We would be happy to advise you on how to successfully navigate through the various stages of robotisation. Subscribe to our newsletter to keep up to date with automation and robotics news and trends - so you can learn about solutions that will help you stand out in the market and stay ahead of the competition. Good luck on your way to creating a modern, automated production environment!

FAQ

How long does it take to implement a cobot?
The implementation time depends on the complexity of the processes and the extent of integration into the existing production line. It can be a few weeks for simple processes or several months for more complex projects.

Will the cobot replace the operator on the job?
The aim of the implementation is to optimise processes and relieve employees of monotonous or heavy work. Operators will still be needed for supervisory tasks, quality control or programming, so their function in the company often becomes more creative.

How to choose the right cobot model?
When choosing, it is important to look at lifting capacity, reach, number of axes, as well as the ability to expand with additional tools. It will be helpful to pre-determine your needs and then consult specialists who can advise on the optimal solution.