Technology’s impact on the future of work has always been an emotive talking point, though when explored further, has been widely unfounded. Primarily as many of the tasks undertaken by robots, have been end of line, labour intensive applications that are not suitable for manual processing, by a human; they exist within an environment deemed not safe for human occupation; the process itself is not one that can be achieved efficiently, without being automated – consider high volume testing, or highly repetitive scenarios.
Whilst robotics and automation have been widely accepted, and adopted within the manufacturing arena of late, the recent pandemic has resurfaced concerns that there might be an increase in labour replacing automation, to mitigate against any future impact upon labour availability. To an extent this statement is true but let us expand upon why it can only be a good thing, for both manufacturers and for those workers whom are ‘at the coal face’.
COVID-19 has forced manufacturers to re-evaluate their operational processes, to ensure that high impact downstream applications, such as stacking and palletising or routine operations, can continue through the implementation of robotics – supported operational efficiencies. Whilst employees are relocated within the operation to areas where they can add value, utilise key skills and be upskilled, thus increasing worker productivity and diversifying operational capability.
The ability to continue to operate in the face of adversity has seen many businesses take drastic steps to safeguard their future stability and save costs. Many businesses are now realigning their business plans to feature automation, to ‘future proof’ their process lines. Future proofing essentially means that technology, processes and people are aligned for the future benefit of the business, and as technology evolves businesses are empowered to not only use robots that are safe to work in unison along-side humans, but to adopt lights-out methodologies – continuous automated operations that can boost productivity in a lights-out environment, with little or no human intervention. Consider a factory that manufacturers components intended for use in high a dexterity, assembly scenario. The robots manufacture at night (lights-out) undertaking the mundane, repetitive aspects of the production process and during the day employees undertake the delicate, assembly tasks that are not suited to robots. Tasks that require an eye for detail, that might consist of multiple component iterations. This is where automation comes into its own, as a process value-add, not as a human/operator replacement, and this is key – ‘Value add’.
A great example of adding value is Rotherham based manufacturer, ZND, producers of temporary fencing who replaced manual methods with automated, to improve upon both quality considerations and to optimise productivity. Having previously relied upon a manual process, that involved a lot of handling, lifting, twisting… strenuous, non-ergonomic movements and tasks, ZND were not producing a product that met with their, nor their client’s quality expectations. Made from tubular metallic components operators welded the parts, including infill tubes together, which compromised quality as the weld pierced the surface of the metal, that then had to be treated prior to distribution, a process that increased production costs. Now, by brazing the components together, product integrity is sustained, and the robots are undertaking the bending, twisting, lifting, and stacking tasks, for which they are designed to execute time and again. The operators in turn, have now been upskilled in other areas of the operation.
The cell can produce 500 barriers in one eight-hour shift, compared to between 50 and 100 across a two-man team over a one-day period. This upshift in productivity has meant that ZND have had to invest in additional manpower across its UK business in various departments, to allow for the increase in volumes that they are now capable of producing. Having two cells means ZND’s output capabilities are now 1000 barriers per eight-hour shift, or 3000 barriers per day – Those figures are extraordinary and have allowed ZND to continue to operate relatively normally, with no disruption from COVID-19.
Robotic process automation, such as that referenced above, when applied within the right areas can not only provide a competitive advantage, but also future proof operations, and support business growth. ZND has continued to grow year on year since 2010 when its first robotic cell was introduced. They now own 11 KUKA robots across their factory floor. But the key consideration here, is the robots have not had a negative impact upon the workforce, they have in fact complimented and increased employee numbers.
Automated manufacturing has and shall continue to form an integral part of supply chains, and the opportunities that automated technology and robots can afford businesses are extensive. We shouldn’t be afraid of robots, instead embrace them for what they are; programmable devices designed to support process optimisation.
