Getting Started with Collaborative Robots PDF

E  1 Contents Lean robotics overview 2 Introduction 4 Step 1: Learn what cobots can do 6 Step 2: Decide what to automate...

E  1 Contents Lean robotics overview 2 Introduction 4 Step 1: Learn what cobots can do 6 Step 2: Decide what to automate 9 Step 3: Build a cobot deployment team 20 Step 4: Bring management and the workforce on board 25 Step 5: Start the design phase 29 What’s next? Buy your cobot 3​0 About Robotiq 3​2  2 Lean robotics: simplify robotic cell deployments If you ask whether robots could work in your factory, the answer you’ll get is probably a hesitant “It depends.” It depends on your factory, your team, which robot you choose, what you want it to do… and a whole lot more. So if you're a first-time robot user, how can you get started? How do you get from your initial idea to a productive, working robot? And if you’ve already got a few robotic deployments under your belt, how can you scale up your robotics efforts throughout your factory—or across multiple factories? The answers can be found in​ lean robotics: a methodology for simplifying robotic cell deployments​. Lean robotics is a systematic way to complete the robotic cell deployment cycle, from design to integration and operation. It will empower your team to deploy robots quicker and more efficiently than ever before. Lean robotics divides robotic cell deployments into three phases: design, integrate, and operate. Robotiq’s library of eBooks covers each phase of robotic cell deployment, giving you access to advice from robotics experts each step of the way. Learn more about lean robotics at​ l​ eanrobotics.org​.  3 This eBook covers preparation for lean robotics This eBook is about preparing for your robotic integration. Preparation comes before the three phases of lean robotics—design, integrate, and operate—and should be completed b ​ efore​ starting the Design phase. This preparation consists of defining the scope of your project, getting your team on board, and presenting the project to management and the workforce. In a way, you’ve been preparing ever since you first had the idea of using collaborative robots. By the end of your preparation, you’ll have an idea of what to automate, the support of your company, and an enthusiastic team who will lead the robotic cell deployment.  4 Introduction At businesses everywhere, people are asking: How can we thrive and grow despite a shortage of skilled workers? How can we increase production quality and quantity while keeping costs down? How can we scale up a high-mix, low-volume operation? All these challenges can be overcome using collaborative robots. However, even though it’s generally accepted that robots are part of the manufacturing industry’s future—and the benefits of automation are widely recognized—smaller companies with limited resources can find it hard to know where to begin. That's where this eBook series comes in! Getting Started with Cobots​ eBooks We’ve produced three eBooks that will teach you everything you need to know about collaborative robots (aka “cobots”) to hit the ground running. Part 1: Kick-Starting Your Project. ​In the first eBook, you’ll learn how to set up your cobot project so success is assured from the start. Part 2: Shopping for a Robot​. ​In the second eBook, you’ll learn how to select a cobot that suits your needs and plan your cobot cell. Part 3: Scaling Your Robotic Capabilities​. ​In the final eBook, you’ll learn how to build on the success of your first cobot project and continue growing. Start production faster with cobots One of the major benefits of collaborative robots is that they’re very flexible and easy to deploy. When you approach cobot cell deployment the right way, you can start production very quickly. As a result, the return on investment (ROI) comes much sooner than with other automation methods. However, you need to be smart about how you plan and implement the deployment. That’s why we developed the lean robotics framework to help you get your robots off the ground as soon as possible.  5 How can your business get started with robotics? The short answer is: Start small. Get going today. Build on your success. In this series, we'll show you how. The first step to an effective deployment is proper preparation. In this eBook, we cover the basics of effective preparation in five steps: 1. Learn what cobots can do. 2. Decide what to automate. 3. Build a cobot deployment team. 4. Bring management and the workforce on board. 5. Start the design phase. Each step builds on the last, so we suggest completing them in order. Let’s go!  6 Step 1: Learn what cobots can do In this section, we’ll look at the amazing opportunities that cobots open up. Although cobots are a relatively new technology, this doesn’t mean they’re hard to use. In fact, cobots​ ​are​ ​designed​ ​to​ ​be​ ​easier​ ​to​ operate ​than​ ​traditional​ ​industrial​ ​robots. In this section, we’ll cover: The difference between cobots and industrial robots. Which applications cobots can be used for. Until fairly recently, if you wanted to automate a process with robots, the only option was industrial robots. These are what most people think of when they imagine robots: big, heavy, dangerous, and expensive. Industrial robots evolved to satisfy the needs of high-volume production, like that found in the automotive, aerospace, and consumer goods industries. Cobots, by contrast, were created for the sort of high-mix manufacturing found in most small-to-medium sized enterprises​ ​(SMEs). Industrial robots and cobots have many similarities. However, cobots have some unique benefits that make them a great fit for many businesses—not just SMEs. Just consider the table below. ⓘ ​Note Cobots allow you to perform the same tasks as industrial robots, but with a smaller investment and much greater flexibility in terms of setup and footprint.  7 Benefits of industrial robots vs. cobots Industrial Robots Cobots Move parts around ✓ ✓ Follow a path/trajectory ✓ ✓ Work autonomously for extended periods of time ✓ ✓ Increase productivity and product quality ✓ ✓ Reduce musculoskeletal injuries in workers (e.g. RSI) ✓ ✓ Require sensors and/or fencing for safety ✓ Require extensive robotics knowledge to integrate ✓ Take up lots of floor space ✓ Are expensive ✓ Are easy for non-experts to program ✓ Are easy to slot into your existing workspace ✓ Are easy to reconfigure for new tasks ✓ Are easy to move from one task to another ✓ Are quick to set up ✓ Cobot applications Cobots can be used for a huge variety of tasks. We’re constantly amazed by the new applications companies come up with (like the ones featured in our ever-growing ​case study library​).  8 However, a few applications crop up time and again (and we’ll cover them in detail later in this eBook). The top five most common ​cobot​ ​applications are: 1. Machine tending​. The robot moves parts in and out of a machine for processing. While the robot loads and unloads the​ ​part,​ ​human ​operators​ ​are free to​ ​work​ ​on​ ​other​ ​tasks. 2. Pick-and-place​. The robot moves a part from the output of one process to the input of another. For example, it could grab parts from a bin and arrange them in order on a tray. 3. Assembly​. The robot performs simple part-assembly tasks that require low dexterity. (On the other hand, assembly tasks that require ​high dexterity are a perfect fit for human-robot collaboration: the robot can perform the simplest assembly tasks, then move parts into an area where the human operator can ​finish​ ​the​ ​assembly​ ​process.) 4. Quality testing​. The robot loads products into a quality testing machine and removes them once testing is complete. 5. Other lightweight applications​. The robot performs basic packaging, finishing, gluing, and other such tasks. Remember, cobots can do most of the tasks that humans do, so long as they don’t require great dexterity. You’ll notice most of these applications involve non-value-added tasks (i.e., tasks that do not add something to a product that the customer would be willing to pay for). That’s because non-value-added tasks are easy for cobots to perform, and they liberate humans ​from​ ​tedious​, ​repetitive​ work. By this point, you might be feeling eager to buy your robot and get started with one of these applications. But first, you must get a clear idea of which applications and processes within​ ​your​ ​company​ ​are​ the ​best​ ​candidates​ ​for​ ​automation—which brings us to the next section.  9 Step 2: Decide what to automate Before you move forward in your robotic cell deployment, you should decide which manual (i.e., human-operated) process you want to automate first. You’ve probably already got a few tasks in mind for automation, which is great. However, as we’ll see in a moment, not every task is equal when it comes to cobots. You might like to download our ​Manual Task Map Template​ to help you work through this section. ⚠ Important Before you read on, write a list of all the manual processes to which you'd like to add a robot. Don't worry about the feasibility of these applications yet. Just get all your ideas out of your head. Maybe you have only one application in mind, in which case just write the one. However, if you can come up with some more ideas, that’s even better. This list will give you a good starting point. It indicates the processes you think are inefficient and that have room for improvement. In this section, we’ll cover: How to pick your first cobot application. The top three easy-to-implement cobot tasks—all great options for your first application. The top three tasks that require extra sensors (and are thus a bit more challenging). Seven factors that create automation challenges.  10 Choose your first cobot application Task feasibility Look again at your list of potential tasks to automate and try to identify the applications that would be easiest for you and your team to automate. ⓘ ​Note Although a particular task might seem like a good candidate for automation (perhaps because it’s boring and repetitive), it might not be the best fit for cobots. That’s because cobots and humans have very different “skill sets”: what’s easy for a human is not always easy for a cobot. For your first cobot application, it's best to start small and keep it simple. You can build up to more complex applications after you’ve gained more experience with cobots. The ideal cobot tasks have two properties: 1. Highly predictable​. The task is the same every time, with few deviations. 2. Repeatable​. The task will be performed over and over again. Many tasks have one of these properties but not the other. For example, making a pizza is highly repeatable—your local pizza shop makes many pizzas every day—but it’s not very predictable, because the dough, sauce, and toppings vary between pizzas. On the other hand, building a toy house out of Lego bricks for your child is highly predictable—the bricks are all the same size and shape, and the task has a defined sequence—but it’s not repeatable because you only need to build one toy house. (That is, unless you're planning to become the neighborhood’s designated Lego assembler.) Make sure you choose a task that is both highly predictable and repeatable. Task predictability Tasks are highly predictable when the objects to be manipulated are always the same and they always arrive at the same location. Here are some properties of highly predictable tasks:  11 Ordered objects​. A series of objects that is always handled in the same order. Your cobot can repeat this order again and again. Similar objects​. Objects with the same or very similar dimensions, weight range, physical form, etc. This allows for quick changeovers between products without the need to change tools. Regular objects​. Objects with little variation from one to another. (By contrast, potatoes are an example of objects that are all similar but not regular.) Your cobot can handle some irregularity with ​the right choice of gripper​, but regular objects are much easier to work with. Regular part presentation​. Objects are arranged in a deliberate, consistent order. Matrices and trays are often used for part presentation: processes involving fixed matrices are the easiest to automate, whereas with trays you can program your cobot to remove the empty tray and bring a new tray to the same​ ​spot​ ​for parts to be picked again. Task repeatability Tasks are repeatable when the steps of the task are the same every time and are repeated over and over again. Here are some properties of repeatable tasks: Consistent operation​. T​ he task does not vary between objects in a batch and does not vary (much) between different batches. Long-term operation​. The operation will be performed many times. (You wouldn't go to the trouble of automating a unique, one-time-only operation.) High-demand operation​. The best cobot applications tackle high-demand operations (i.e., those which are needed constantly). You can use robots for low-demand operations, but they’re not usually the best option. ⓘ ​Tip A picture (or video) is worth a thousand trips to the shop floor. We highly recommend taking pictures and videos of the cell you want to automate. This will help you define each step of the application. Plus, you’ll be able to examine the application​ ​from​ ​your​ ​desk​—instead​ ​of​ ​waiting​ ​for​ ​someone​ ​to​ ​perform​ ​it every time you need to take a closer look at something.  12 Three easy-to-implement cobot tasks Although a huge array of different tasks are suitable for automation, we see these common applications again and again. They’re generally the easiest to integrate, which makes them a good choice for your first robot project. 1. Machine tending By far the most popular application is machine tending. It's also one of the easiest, because it involves minimal programming, no extra sensors, and (if you don't overcomplicate it) no need to communicate with other equipment. Machine tending means using a robot to load and unload a machine, such as a CNC milling machine, 3D printer, or labeling machine. This removes a lot of non-value-added work, since a human operator no longer needs to be standing over the machine the whole time. A similar application is quality testing, which involves loading products into a quality testing machine. If this all sounds good to you, check out our ​Machine Tending Guide​. Also see our L​ owercase case study​ for a real-life example of a machine-tending application. 2. Pick and place This is our second most popular application. It involves having the robot move objects from one area of its workspace to another. Pick and place can be even easier to implement than machine tending, if the objects are well-ordered and of similar shapes and sizes, and no extra sensors are needed. See our B ​ eyerdynamic case study​ for a real-life example of a pick-and-place application. ⓘ ​Tip Universal Robots (UR) offers ​wizards to help you automate these simple picking applications. UR's wizards are embedded in the robot controller and can be engaged very quickly.  13 3. Dispensing Dispensing tasks, such as gluing, are a great first task for robots. You simply move the robot's end effector around the desired path and it repeats the task the same way every time. See our simple g ​ luing application​ for a real-life example of a dispensing task. Three tasks that require extra sensors The next step up in terms of difficulty are tasks that require additional sensors. These may not be the best option for your first robot application. 1. Finishing (with force sensors) Finishing involves using the robot to move a finishing tool (such as a buffing tip) over the surface of a product. Finishing usually requires a force sensor because the tool must be held against the object’s surface with constant pressure. If you must use a force sensor, the ​Robotiq Force Sensor can be attached to the robot in minutes, which makes integration much easier than it was in the past. Force sensors are also useful for this task because finishing requires the robot to follow complex paths. See our ​Saint-Gobain case study for a real-life example of how the team used force sensor path recording for a finishing application. 2. Assembly (with force sensors) Assembly can mean many things, but it often requires pushing parts together with controlled force. As a result, this task is helped by adding a force sensor to the robot. Traditionally, force assembly actions have been difficult to program. However, ​Robotiq Skills allow you to add these capabilities without the need for complex programming. See our S ​ piral Search Skill​ for a real-life example of what is possible with Robotiq Skills. 3. Pick and place (with vision sensors) Pick-and-place applications can be made more flexible by adding a vision sensor to detect the position and orientation of objects. Traditionally, it was challenging to add vision to robots. However, the Robotiq ​Vision Sensor​—with its intuitive t​ emplate learning tool​—has made it a lot easier.  14 See our A ​ ssa Abloy case study​ for a real-life example of a vision-guided pick-and-place application. ⓘ ​How to tell whether you’ll need extra sensors Ask yourself the three questions below; your answers will indicate what additional sensors​ ​you​ ​might​ ​need​ ​to​ ​use. Most cobots consist of a single arm. For a quick suitability test, try performing the task manually with one hand behind your back. →​ Could you perform the task one-handed? Cobots don't always have tactile or force feedback. To simulate a lack of tactile feedback, try performing the task using a pair of pliers instead of your fingers to pick up the objects. →​ Could you perform the task without any tactile feedback? Imagine performing the task with your eyes shut. This gives you a clue as to how important vision is to the task. For example, inspecting parts for defects and sorting them by color could both require vision. →​ Could you perform the task while blindfolded? Seven factors that create automation challenges Sometimes people's initial ideas for robot applications aren’t the best choice for a first project. This is because they include one or more of the seven most challenging factors. We recommend avoiding applications that include them because they’ll require you to spend more time, energy, and money deploying your robot. Although these factors may seem simple at first, they quickly turn into headaches. The best strategy is to start small and work your way up to more complex projects over time.  15 1. Unstructured part presentation As humans, it's easy for us to throw objects into a box or bucket and take them out again later. Not so for robots. Although advanced sensing has made it possible for them to pick up unstructured objects, it’s much easier and more efficient to simply structure the objects correctly in the first place. 2. Widely divergent objects People can handle a near-infinite variety of objects. For example, you could be presented with a jumbled box of wildly varied fruits and you’ll still find a way to arrange them into an attractive fruit bowl. Robots, on the other hand, need much more predictability. For instance, you could probably program a pick-and-place application for apples and oranges (which are of similar shape and size). But, there’d be trouble if you spontaneously passed your robot a banana.  16 3. Conveyors Conveyor belts are common in factory automation—which leads people to assume they’re the best way to present objects to cobots. In reality, conveyors present a big integration challenge. You often have to add a vision system or part detection sensors in order to detect the moving objects, and you need advanced programming to get the robot to move to the right position and grasp the moving objects. Our ​case study of WALT Machine, Inc. is a perfect example. The company’s president, Tommy Caughey, was initially considering a conveyor solution. However, he found that the Robotiq Camera was a much simpler solution. With it, he was able to increase daily production by 100%. 4. Complex sensing If you find yourself asking "Is it possible to detect this with a sensor?", the answer is probably "Yes… but it's not the best idea." ​Some sensors are easy to integrate with cobots, but more advanced sensors are a challenge. For example, with the new fixed laser-light camera systems—which build 3D models of objects and the robot’s environment—it’s possible to both detect an object in 3D and calculate the best grasping configuration. However, this task is complicated enough to form the basis of an entire ​research study​. In real-world situations, it's better to use simpler sensors, or (if possible) none at all.  17 5. Integration with other machines Imagine you're setting up a robot to tend a CNC machine. What’s the best way for the robot to tell the machine to start the CNC operation? People's first answer is usually something like "We'll program the robot to send a signal to the CNC." This is overcomplicated. Integration with other machines may not be the toughest programming challenge, but there are much simpler ways to achieve the same effect. For example, you could get the robot to physically push the start button on the CNC machine. This takes minutes to program rather than hours. If digital communication is vital, it's easier to attach a wire to the digital inputs and outputs of each machine than to use communication protocols. 6. Logic Humans are natural problem-solvers. If we see an object turned upside-down in the part presentation tray then we’ll flip it over. If we’re handed a baseball bat then we grasp it one way; if we’re handed a kitten then we grasp it another way. This type of logic comes easily to us. For robots, every decision to be made adds a layer of programming complexity. You can spot logical decisions by looking out for phrases with "If… then." Try to eliminate these wherever possible.  18 7. Advanced force control Getting your robot to move between two points in a straight line is simple. Getting your robot to apply a specific force for the duration of its movement is more difficult. With Robotiq Skills, some force-control tasks (like ​torque turning​) are now easier than ever to integrate. However, the more advanced types of force control require complex programming.  19 Final thoughts on choosing a task You should now have a basic understanding of what makes a great (and not-so-great) first robot application. In summary: Cobots are great at pick and place, material handling, and material dispensing. Applications that require extra sensing—e.g. finishing, assembly, and vision-guided pick and place—are not ideal for a first robot project. (Although with ​Robotiq sensors​, these applications aren’t as challenging as they used to be.) Other poor choices are those that require complex sensing, unstructured and divergent objects, moving objects, force control, logic, and integration with other machines. In our experience, people get the most out of cobots by starting simple and gradually​ ​building​ ​up​ ​their​ ​expertise over time. Now you just need to decide which task to automate! Download the ​Manual Task Mapping Template to help outline your chosen task, or use the ​Blueprints interactive tool​.  20 Step 3: Build a cobot deployment team One of the biggest challenges of introducing robots in the workplace is convincing the rest of the team that it's a good idea. There are a lot of misperceptions about robots. Some people believe that as soon as a robot enters​ ​a​ ​plant,​ ​the​ ​”robot​ ​takeover​” ​isn't ​far​ ​behind.​ People start to fear for their jobs. ⓘ ​Note The goal of cobots is not to eliminate jobs by replacing human labor. The goal is to eliminate monotonous and repetitive tasks so humans can focus on more value-added tasks. This boosts productivity, prosperity, and worker morale. But how do you convince your workforce to embrace cobots, not fear them? The best way is to start with a small team of "mobilizers"—key people who will champion the effort to bring cobots to the business. Recruit team members A successful cobot deployment team must have expertise in the following areas: 1. Robotics 2. Project management 3. Your manufacturing process  21 This expertise is spread across ten key roles: Manufacturing manager Programmer Project leader Operation and maintenance worker Project coordinator Process advisor Engineer Procurement specialist Installer Continuous improvement specialist That doesn't mean you need ten people on your deployment team. It’s quite likely that some people will take on two or more responsibilities.  22 Together, you and your team will: 1. Build a case for cobots and present it to management (if necessary). 2. Announce the cobots project to the entire workforce and address any concerns. 3. Lead and/or perform the cobot deployment. Clearly, it's important to get the right people on your team! Download the ​Team Roles and Responsibilities spreadsheet​ for an outline of each role’s objectives, key responsibilities, and metrics. Explain the benefits of cobots Your team members may have concerns about cobots, such as fears of job cuts, uncertainty about the technology, or worries that the project will fail. Addressing these concerns now will make it easier for your team to convince the rest of the workforce later. To get the conversation started, here are what we see as the top three benefits of cobots: Benefit 1: Greater job security Many people are afraid they’ll lose their jobs if a robot comes into the factory. It's important to tackle this concern right away by reassuring your team that their jobs are secure. At every plant where we’ve seen cobots introduced, management did not cut jobs. Instead, workers were transferred to other processes that require more dexterity and human intelligence. We've even seen cobots lead to more jobs being created. Cobots create a shift in labor on your production floor, allowing you to move workers to more value-added tasks—which increases your production. As a result,​ ​you​ ​will​ ​likely​ ​need​ ​to​ ​hire​ ​more​ ​people​ ​down​ ​the​ ​line​ ​to​ ​handle​ ​the​ ​increase. We’ve also seen businesses use cobots to “onshore” manufacturing operations (i.e., move them back to the country of origin). One example is ​Lowercase​, which moved eyewear production from China back to the US. This trend contributes to even greater job security. Your team will appreciate it if you guarantee them that staff numbers will not be reduced when you introduce collaborative robots.  23 Benefit 2: Fewer injuries One of the more practical benefits of collaborative robots is that they can improve ergonomic issues in the workplace. The tasks at which robots excel—those involving repetitive movements—are precisely the sort that injure workers. Repetitive movements can cause musculoskeletal disorders, and in some industries, many workdays lost due to injuries. O ​ ne study​ found that 35% of lost workdays were attributable to these disorders. Practically everyone can relate to the benefit of cobots here, especially since many people who work on the front line have experienced some sort of muscular complaint. By highlighting this benefit, your team will appreciate how cobots can improve their experience at work. Benefit 3: More interesting jobs Robots are good at boring tasks (as in uninteresting tasks—not "boring" as in drilling holes… although they’re good at that too!). Tending a CNC machine, for example, is neither fun nor stimulating. Such tasks can ruin an otherwise great day at work. By contrast, setups, quality inspections, and robot programming are much more stimulating tasks for your employees. Nobody likes to do dull tasks. However, every business has some boring but necessary jobs which someone has to do. Every time you get a collaborative robot to perform a boring task, it means you can move an employee to a more interesting task that uses their skills more effectively. Stimulating tasks result in a workforce that is happier and more motivated. Your team will appreciate the benefits of cobots when you highlight how their jobs will become more interesting. In most cases, any fear of robots that existed before the first application is quickly forgotten after the first robot is installed. People quickly realize how much the robot can help them in their work. Sometimes they even give the robots nicknames! For example, at ​Scott Fetzer Electrical in the USA, workers dubbed a pair of collaborating robots​ ​”Thelma ​and​ ​Louise.” Record the plan Get your team together, and create a written document that includes the following four points: Why​. Why cobots and why now? Make sure you’re 100% clear on why cobots are a good idea. After this is decided, the “how” becomes much easier. Scope​. Clarify which manual cell you’re going to automate. Define the start and end points of the robotic process.  24 Schedule​. Decide on a realistic time frame for the project and set a date by which the cobot cell should be up and running. Roles​. Make sure everyone’s clear about his or her roles and responsibilities. Take the opportunity to double check that all ten roles have been filled. Once your team has agreed on roles and responsibilities, and been made aware of the benefits of cobots, you’re ready to move forward with the project.  25 Step 4: Bring management and the workforce on board You’ve chosen your application… You’ve brought your team on board… And now you’re almost ready to get started on the Design phase of cobot deployment! But before you announce your cobot project, it’s important to present a solid case for cobots. You and your team are already convinced of the benefits. This step simply involves clarifying those benefits in a way that management and the workforce will understand. In this section, we’ll cover: 1. Setting metrics for your cobot deployment. 2. Presenting a case for cobots that management will love. 3. Presenting a case for cobots that the workforce will appreciate. Set metrics for your cobot deployment To be convincing, you have to get specific about the benefits of your proposal. That’s why metrics are the key to building a data-driven case for cobots. They let you go from this: "We want to introduce a machine tending cobot because it will boost productivity”​… To this: "We want to introduce a machine tending cobot to the milling CNC machine. This will increase the machine's throughput by 20% over four months and improve quality consistency, with a payback period of one year." Here are five metrics to choose from, along with questions you and your team should answer: 1. Quality People assume the main benefit of robots is speed (performing tasks faster). That’s a misunderstanding. The main benefit of robots—and cobots—is that they perform tasks the same way every time, leading to better quality and consistency of output.  26 Consider: How many ​nonconformities ​are produced by ​this​ ​cell? What​ ​is​ ​the​ ​total​ ​cost​ ​of​ ​these​ nonconformities? 2. Throughput Cobots have the potential to increase a cell’s throughput. Sometimes this is because the robot works faster than a human could, but it’s more often because it can work 24/7 without breaks. Consider: What​ ​is​ ​the​ manual cell’s throughput? What is the cycle time for the manual process? (You should aim to keep the robot’s cycle time within a consistent range to ensure it’s really improving operations.) 3. ROI​ ​potential Cobots usually have a quick payback period compared to traditional industrial robots. For example, 3D printing company Voodoo Manufacturing earned a ROI in just six months (see the c​ ase study​ for details). Consider: What are the costs​ ​associated​ ​with​ ​automating​ ​this​ ​process? Do the benefits (e.g. increased output, improved quality, 24/7 availability, and greater work satisfaction​) ​justify​ ​the​ ​investment? 4. Time Cobots can increase your employees’ productive time. By moving a worker to a greater value-added task, you increase that worker's productivity. Plus, cobots reduce downtime because they work without slowing down or taking breaks. Consider: How often, and for how long, does downtime occur now? Which value-added tasks elsewhere in the process are currently understaffed? 5. Value In business, value refers to anything the customer is willing to pay for. That doesn’t mean all non-value-added operations are unnecessary. Some, like packaging, must be done. By assigning these tasks to cobots, you and your employees are free to focus on operations that create value.  27 In the lean robotics methodology, we also consider value at another level: within the robotic cell itself. Here, the customer is defined as the next cell in the process, so value-added operations are anything that create value for the next cell. Consider: How would the cobot affect the value created for the end customer? How would the cobot affect the value created for the next cell along in the process? Some of these metrics are straightforward to quantify (like ROI and throughput). Others are more qualitative, and may require some lateral thinking (like quality and value). Build a case management will love Unless you work at a small startup, you’re in charge of everything, or both, you’ll have to propose your cobot project to management. Your task is to show them why cobots are a great idea. The key is to describe the specific benefits (backed up by your metrics) using "management language." This doesn't mean business buzzwords, sales slang, or junior-executive jargon: it means finding out what’s most important to management and framing the benefits of cobots in terms they’ll appreciate. The basic steps are: 1. Consider how receptive management is to the idea of automation. 2. Clarify your own goals for cobots. 3. Define management’s main goals and desires. 4. Address potential concerns about automation. 5. "Translate" the benefits of cobots into terms management will love. 6. Build your proposal and take steps to de-risk the decision. 7. Set up the perfect time and situation to make your pitch. Download our workbook, ​How to Convince Your Boss to Go With Cobots​, for help completing this process. Build a case the workforce will appreciate Pitching cobots to the workforce is another challenge. If​ workers​ ​don’t​ ​want​ ​the​ ​robot​ ​to​ ​work,​ ​it​ ​won’t​ ​work!  28 Robots aren’t just another piece of equipment. Employees won’t care when there’s a new printer at work, for instance, but they often have doubts and fears about robots. Most people have never heard of collaborative robots. They aren’t aware of the difference between cobots and full automation. When people aren’t told what’s going on, they tend to assume the worst. Rumors move fast. Once misconceptions spread, they’re hard to get rid of. It’s much easier to simply provide the right information in the first place. While it’s important to explain the value of cobots, you also need to listen to people’s opinions and address their concerns. One of the best ways to do so is to hold a "kick-off session" to announce the project. Before it happens, gather your team of mobilizers and prepare the following: A list of questions workers are likely to ask, along with answers that genuinely address the concerns behind these questions. Videos and images of collaborative robots working in similar facilities to yours, so people see how well they work alongside humans. Check out our ​case study library​ for examples! Documents with more information about the project, which should be made available to members of the workforce. Make sure to leave lots of time for questions at the end of the kick-off session. It’s also a good idea to arrange one-on-one meetings with team members to address any lingering concerns or questions.  29 Step 5: Start the design phase Once everyone’s as excited about cobots as you are (or at least receptive to the idea) it's time to design your cell! The design phase is the first major phase of the l​ ean robotics framework​. Before starting this phase, you should have defined: The scope of the project (your chosen cobot application) Roles and responsibilities The project’s timeline/schedule (That’s what you accomplished by working through this eBook!) In the design phase, you will build on this work. You and your team will: 1. Create a manual task map and layout. 2. Create a robot task map and layout. 3. Compare the manual and robot task maps. 4. Finalize the robotic cell concept. To learn about the Design phase, download the ​Lean Robotics book and jump to the section "Phase 1: Design." Take a shortcut with Blueprints Want to speed up your cobot deployment and start seeing those benefits even sooner? We’re here to help! Use our ​online Blueprints tool to describe the manual task you want to automate, and one of our coaches will get in touch for a free consultation.  30 What’s next? Buy your cobot Congratulations! You’ve identified potential robotic applications in your factory, assessed the feasibility of automation, reassured everyone, and convinced management to move forward. Now what? You’ve got your copy of ​Lean Robotics​, so you know how to start the Design phase. You’ve created a ​Blueprints​ account, scheduled a free coaching session, and can’t wait to learn more! But you’ve begun to wonder: isn’t something missing… like the actual robot?! Yep, it’s time to go shopping for your first cobot. Go on to the next eBook in our Getting Started with Collaborative Robots series—​Shopping for a Collaborative Robot​—and learn how to find the perfect cobot for your project.  31 About Robotiq Robotiq’s lean robotics methodology and products enable manufacturers to deploy productive robotic cells across their factory. Manufacturers leverage the lean robotics methodology for faster time to production and increased productivity from their robots. Production engineers standardize on Robotiq’s Plug + Play Components for their ease of programming, built-in integration, and adaptability to many processes. They rely on Flow’s software suite to accelerate robot projects and optimize robot performance once in production. Robotiq is the humans behind the robots: an employee-owned business with a passionate team and an international partner network.  32 Let’s keep in touch For any questions concerning robotic and automated handling or if you want to learn more about the advantages of using flexible electric handling tools, contact us. Join us on social media: Workfloor: Robotiq’s Twitter Blog Linkedin Facebook Youtube Google​+ Robotiq’s community where industrial a​ utomation Pros share their k ​ now-how​ and ​get answers robotiq.com​ | leanrobotics.org