Robot integration brings high-precision manufacturing to mid-market manufacturers

High-precision manufacturing was once considered something exclusive to large companies. However, advances in robotic integration and automated manufacturing have changed this perception.

Sophisticated features are becoming accessible to the mid-market and smaller operations. This change has led to a more competitive landscape.

Smaller manufacturers have the opportunity to reach new levels of precision and efficiency. Today’s robotic systems can help these manufacturers modernize targeted workflows without overhauling their entire manufacturing operations.

Robotic innovations drive efficiency for manufacturers

The evolution of robotics has led to more democratized precision manufacturing processes. This is evident in industrial robots and agile collaborative robots.

Key benefits of these innovations may include:

• Cost and size: The potential for lower investment costs and compact designs can make robotic systems economically viable. It can also make it easier to integrate into existing layouts.
• Advanced programming: Intuitive interfaces and guided teaching methods support rapid deployment and reconfiguration. This reduces the training typically required for operators without robotics experience.
• Sensors and features based on artificial intelligence: Sensors, such as vision systems and force-torque sensors, can be integrated with artificial intelligence. This allows robots to understand, react and adapt precisely.
• Security and collaboration: Cobots can work safely alongside humans without having to resort to extensive protection. This fosters a flexible human-robot workforce that combines optimal use and human dexterity.

These advances mean that middle-market manufacturers can overcome obstacles such as skilled labor shortages, rising costs and quality demands.

Real-world impact of robotic integration for precision manufacturers

Here are some use cases that show how a wide range of manufacturers have benefited from recent advances in robotics.

1. SCHUNK R-C2 automation for flexible production

Torneria Novoletto is an Italian organization specializing in sophisticated components for the chemical, medical and pharmaceutical sectors.

The company faced obstacles in achieving high process accuracy and reliability for medium-sized batches. It implemented SCHUNK’s R-C2 automation concept, integrating advanced clamping devices and grippers with robotic handling.

The introduction of this system has helped support high operational flexibility. Setup and process changeover times have also been significantly reduced because the SCHUNK R-C2 allows continuous management of part dimensions and automated clamping.

This innovative robotic integration has helped Torneria Novoletto pursue 24/7 unmanned operation, increase machine utilization, and mitigate skilled labor shortages.

2. Cobot integration for part marking

Telesis, a leading provider of industrial marking solutions, has integrated its part marking technology with systems from Universal Robots.

The company offers advanced laser and dot-percussion markers. When a Telesis laser marking system is integrated with a UR robotic arm with limited strength and power, it creates a precise and flexible method for identifying automated parts.

Innovations like this ensure that systems can be deployed safely alongside human workers. The robotic integrations provided Telesis with an optimized marking process without complex safety wraps, consistent high-quality marking across various materials and part geometries, and increased traceability and quality control.

3. FANUC M-20 robots improve productivity and scalability

Northern Kentucky Machine (NKM), a flexible machine shop, has experienced labor shortages and production capacity challenges. Its strategic response involved the use of automated manufacturing solutions, such as the deployment of FANUC M-20 series industrial robots.

Using Automation Within Reach’s (AWR) “RC-2” CNC machine tending system, the integration increased NKM’s productivity and machine utilization.

Operators quickly adapted to the programming and operation of these robotic cells. This helped enable “lights-off” manufacturing for longer runs, freeing up human workers for other tasks.

FANUC robots have provided NKM with the scalability to pursue and tackle larger projects, deliver consistent quality parts, drive growth and compete with other mid-sized organizations.

4. ActiNav allows container collection and extension of existing equipment

PrecisionForm Inc. is a manufacturer of small custom metal parts. He took on the challenge of automating bin picking for CNC machines.

Implementing Universal Robots’ ActiNav system, PrecisionForm integrated a UR5 cobot with advanced vision and path planning capabilities. This approach led to reliable picking of parts from deep containers which were then loaded into the CNC machines.

Challenging geometries were less of a problem and operators were free to handle multiple machines. UR cobots have helped reduce labor challenges and extend the life of older CNC equipment.

By adding a relatively low-cost robotic solution, PrecisionForm Inc gained additional utility from existing machinery, increased potential return on investment (ROI) as a mid-market operation, and improved daily production.

Capabilities evolve for mid-market manufacturers

The accessibility of precision manufacturing marks a pivotal moment for many industries. Robotic integration is no longer exclusive to the world’s largest enterprises.

Innovations that deliver ultra-high precision and consistent quality are now economically and operationally feasible for mid-sized manufacturers. The benefits that organizations such as Telesis, Torneria Novoletto, NKM and PrecisionForm have now demonstrated that modern robotics can drive sustainable growth.

Robotic solutions continue to evolve. By doing so, the benefits of automated manufacturing will increase alongside these changes. With thoughtful and careful implementation, a new generation of agile and highly precise manufacturers will be waiting to reap the benefits of this exciting new world.

About the author

Lou Farrell, senior editor of Revolutionizedhe has been writing for years on the topics of robotics, information technology and technology. He has a great passion for the stories he tells and for writing in general.

This article is published with permission.