34 n ROBOTICS AND AUTOMATED MANUFACTURING February 2024 www.drivesncontrols.com Busting the automation myths The UK is the world’s sixth-largest economy, the eighth-largest manufacturing nation, and the thirdbiggest aerospace manufacturer. But there remain concerns around labour shortages and our low productivity rates. These issues are linked to automation. To stay competitive, industrial companies need to produce more goods, to a higher quality and in less time. Since the rst industrial revolution through to the current fourth iteration, automation has been proven to boost productivity. Yet while the UK was once a world leader in adopting automation, we now rank a lowly 25th in the world for robot density, with 98 robots per 10,000 workers. Germany, the leader in Europe, boasts 415 . There are some signs of improved take-up, however. In 2022, 2,534 new robots were installed in the UK – 54% more than in 2015. However, the productivity gap persists and reluctance to invest in automation is still a major issue, especially among SMEs. Much of the lingering reluctance is based on a long-held fear of automation, largely based on myths that need to be debunked. Here, I tackle seven of the most popular misconceptions around robotics and explain why there’s never been a better time to make the move to automation. Myth #1: Automation solves everything Automation is not a magic bullet. If a manufacturer is looking to solve a bottleneck, then automating the process will just mean parts arriving at the bottleneck faster, exacerbating the issue. And nor will problems with quality and consistency be solved simply by installing machines. Instead, factory owners should seek advice from automation experts about their exact needs and what they want to achieve. These experts can help to identify problems with existing processes and advise on how best to employ automation to deliver the required objectives: greater eciency; shorter cycle times; more consistency; and higher quality; leading to improved competitiveness and protability. Myth #2: Automation is too complicated It doesn’t have to be. Businesses can start small, with simple functions such as a palletising /depalletising cell, and progress from there. Automation experts can help identify where manufacturers can get a good return, quickly. When it comes to operation, this doesn’t need to be complicated, either. User-friendly software tools are available with command systems with drop-down menus and choice paths that look comfortingly familiar, making them extremely user-friendly. Myth #3: Automation will replace valued employees The right automation system will replace tasks, not people. The best way to approach a robotics project is to look at what is happening already and identify ways to do it better. Automating processes that are dull, dirty or dangerous helps to reduce sta injuries and overcome quality issues born of boredom, freeing up employees to take on more valueadded tasks. This can improve sta retention rates, boosting morale and impacting productivity positively. Automation can also help to capture experienced employees’expertise. A successful project will involve talking at length to the people who carry out the task and discussing with them how to do it better. By actively engaging shopoor workers, their expertise can be retained. This last point is particularly pertinent, given that almost one fth of employees in UK manufacturing are aged 55 or over, with 20% of the workforce set to retire within the next decade . Myth #4: Why x something that isn’t broken? Our current equipment has been working ne for decades There is no reason why embracing automation should require a company to ditch their current equipment, especially if it is working well. Robots are regularly integrated into existing lines, complementing older machinery to enhance working practices and increase eciency and boost productivity. What’s more, these modern alternatives are designed to last for decades. Not only are today’s automation systems fast, consistent, exible and adaptable, but they are also extremely reliable. Older machinery can require more maintenance to keep it running, meaning more time oine, resulting in unproductive downtime and growing repair costs. By contrast, advanced condition monitoring has almost completely eliminated unforeseen breakdowns and unnecessary part replacements in modern robotics, enabling longer service intervals and increased uptime. Fanuc’s robots, for example, have an eight-year mean time between failures, while our CRX collaborative robot (cobot) series boasts eightyear zero maintenance. Failure to update and invest in new technology erodes competitiveness and risks putting a company out of business. Myth #5: We lack the in-house skills to program a robot The amount of knowledge and expertise that businesses already have on site often comes as a surprise. If employees are used to setting up CNC equipment, they will nd it much easier to set up a robot. Robot software often does not require in-depth knowledge of coding. Today’s Potential users of robotics and other automation equipment are sometimes deterred by beliefs about the equipment that are often unfounded. Carl Patrick, robot sales manager for machine tool automation at Fanuc UK, unpicks some of the myths that are holding UK manufacturers back from investing in automation. Robots are becoming increasingly accessible and aordable for applications such as tending machine tools
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