Imagine repeating the same movement hundreds of times during a shift: picking up a part, placing it in a fixture, waiting for the operation to finish, then moving on to the next part. Each step may take only a moment. Repeated throughout the day, however, the task becomes physically demanding, and small differences in part positioning can affect the result.
Cobots share this kind of repetitive work with operators. Short for “collaborative robots,” cobots work in the same space as people when the application has been properly assessed and the necessary safety measures are in place. The aim is not to take over the operator’s entire job. It is to handle repetitive, physically demanding steps so the operator can focus on other parts of the process.
What does this division of work look like on a production line? Let’s look at welding and assembly.
Sharing repetitive work on the welding line
In welding operations, parts need to be positioned correctly and consistently in the fixture for every cycle. On lines with a wide product range and low or medium production volumes, this task accounts for a significant part of the operator’s daily workload. Small differences in part position can also affect weld quality.
The cobot handles repetitive tasks such as picking up a part and placing it in the fixture. The operator focuses on preparing parts, changing fixtures, monitoring the process and checking quality. Repeating the welding movements with the same program reduces variation between cycles and helps keep the process consistent.
The benefit goes beyond speed. Assigning repetitive movements to the cobot reduces the operator’s physical workload and leaves more time to monitor the process and assess quality.
Making more room for the operator in assembly
Picking and positioning parts, tightening screws, feeding machines and transferring products: these tasks recur throughout the day on assembly lines. A movement that seems simple in a single cycle becomes tiring after hours of repetition.
As the cobot places a part in the fixture, the operator checks the assembly. At another station, the cobot feeds components while the operator assesses the connections and product quality. When the cobot takes on a repeatable task such as screwdriving, the operator can spend more time on inspection and assessment.
On lines where products change frequently, the ease of switching to a new product also matters. Cobot programs can be adapted for different tasks, helping production respond to changing needs.
Productivity means more than cycle time
Cycle time alone does not tell the whole story when assessing an automation application. Quality, the operator’s physical workload, process flow, downtime and product changeovers all affect production performance.
Robots perform programmed movements with a high degree of repeatability. Operators interpret changing conditions, respond to unexpected situations and assess quality. A cobot application brings these contributions together in the same production cell: the cobot handles repetitive movements while the operator focuses on tasks that require monitoring and judgment.
A cobot is not the right choice for every production line. Conventional industrial robots may be better suited to fixed lines running at very high speeds and producing the same product for long periods. Cobots are a strong option for applications with a wider product range and an active operator role. The decision depends on production speed, part design, fixture layout, product changeover frequency and the level of human-robot interaction.
Using a cobot does not, by itself, make a workspace safe. Every application requires a risk assessment. The robot, end effector, part, workspace and operating conditions must be considered together to determine the necessary safety measures.
The right question: Which tasks should we share?
When considering a cobot investment, start by looking at the work rather than counting robots. Which tasks are repeated most often? Which ones place a physical burden on operators? Where can operators contribute more if they have time to focus elsewhere?
A cobot’s role in manufacturing is to create a practical division of work between people and automation. The cobot takes on repetitive movements; the operator focuses on monitoring the process, assessing quality and stepping in when needed. When designed around the needs of the application, this arrangement brings greater order to production and makes the operator’s work more sustainable.
At Dynaress, we support the integration of robotic systems into manufacturing processes through automation software and cobot programming solutions. To discuss how cobots could fit your process, contact us through our contact page.
References
- ISO/TS 15066:2016 – Robots and Robotic Devices
Safety requirements for collaborative industrial robot systems and their working environments:
ISO/TS 15066:2016 - Universal Robots – Arc Welding Applications
Information on the flexibility, precision and repeatability of cobots in welding applications:
Arc Welding Robots - ABB – Collaborative Robots
Information on human–robot collaboration, flexible automation and small- and medium-volume production:
ABB Collaborative Robots - ABB – Cobot Arc Welding Package
An application example demonstrating the use of cobots in welding operations:
Cobot Arc Welding Package