Special Report: a Fresh Look at Robots in Vehicle Manufacturing

Special report: A fresh look at robots in vehicle manufacturing

Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

© 2019 All content copyright Automotive World Ltd. All rights Automotive reserved. World est. 1992 This publication - in whole or in part - may not be shared, copied, reproduced, stored in a retrieval system, or be Automotive World transmitted in any form by any means electronic, mechanical, 1-3 Washington Buildings photocopying, recording or otherwise without the prior Stanwell Road, Penarth, permission of Automotive World Ltd. CF64 2AD, UK Disclaimer www.automotiveworld.com T: +44 (0) 2920 707 021 This report is the product of extensive primary and secondary [email protected] research. It is protected by copyright under the Copyright, Designs and Patents Act 1988. Registered number: 04242884 VAT number: GB 815 220 173 The authors of Automotive World Ltd research reports are drawn from a wide range of professional and academic disciplines. The facts within this report are believed to be CEO & Managing Director: correct at the time of publication but cannot be guaranteed. Gareth Davies The information within this study has been reasonably verified to the author’s and publisher’s ability, but neither accept responsibility for loss arising from decisions based on this Editor-in-Chief : report. Martin Kahl This report contains forward-looking statements that reflect the Contributors : authors’ current views with respect to future events. Such statements are subject to risks and uncertainties. If any of the Betti Hunter assumptions underlying any of these statements prove Jack Hunsley incorrect, then actual results may be materially different from Megan Lampinen those expressed or implied by such statements. The authors do Xavier Boucherat not intend or assume any obligation to update any forward- looking statement, which speaks only as of the date on which it is made. Production: Anmol Mothy All the estimates are based on assumptions, the authors’ calculations and publicly available data. Automotive World Ltd is © Automotive World Ltd 2019 not liable for misrepresentation or misuse of such information or validity of publicly available information.

i Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

Table of contents

Executive summary iii

How robots may help automakers ﬁnally realise Industry 4.0 1

Automaker snapshot: who's doing what with robots 4

Forget the lights-out factory: humans will remain essential 8 for vehicle manufacturing

Automakers need robots that deliver universal solutions 11 and ﬂexibility

Cobots are a crucial step on the path to AI-driven automation 14

Automotive stamping is an increasingly sophisticated business 17

Cost and impact: assembly line robots hit the sweet spot 20

Maximising robotic paint shop potential will require 23 human intelligence

Why in-plant logistics robots are quickly becoming essential 26

Digitally linking robots can enable safer, more eﬃcient 29 manufacturing

Research by Automotive World ii Special report: A fresh look at robots in vehicle manufacturing

Executive summary

• Rapid changes in the automotive industry are manufacturing requests. These robots, driving the development of radical robotics combined with IoT platforms, can allow solutions. Electrification, automation and players to create highly flexible plants that customisation all require automakers and can scale quickly with demand while saving suppliers to take a fresh look at their time and costs manufacturing processes to retain their • Automating painting procedures represents a competitive edge huge potential efficiency saving in the latter • Where automation is accompanying, if not stages of paint application, potentially replacing manual workers on a line, significantly reducing a company’s paint automakers are leveraging advanced artificial usage, waste and overspray intelligence and computer vision to enable • Concern over the impact of automation is workers teach the robots, and for the robots balanced by predictions that there will to learn tasks always be a role for human labour. A June • Some of the industry's top manufacturing 2019 report by Oxford Economics suggests regions are struggling to attract production that by 2030, up to 20 million manufacturing workers. One way to address this is through jobs worldwide could be replaced by robots— greater use of automation, particularly equivalent to 8.5% of the global robots, to help fewer people work more manufacturing workforce. Furthermore, the productively and more safely report found that people displaced from • Automakers in emerging markets in manufacturing jobs would find that particular must carefully weigh up the need comparable roles in the services sector have to offer employment to lower skilled workers also been impacted by automation and in poor local economies with the need • However, Oxford Economics also found that for high degrees of flexibility, repeat increasing automation will boost productivity accuracy, quality, speed and safety and economic growth, and “lead to the • In developed markets, such decisions focus on creation of new jobs in yet-to-exist the need to accommodate an ageing workforce industries” • Automakers are seeking to combine rather • A common theme in discussions about than replace the strengths of humans with increasing automation in vehicle production the strengths of robots. Humans are good at is the need for robots to assist, not replace, reacting quickly to unexpected incidents, the existing human workforce; where once while robots excel at dangerous, repetitive automation was seen as a replacement for and strenuous tasks humans, now it is widely seen as an enhancer • Collaborative robots (cobots), which can of human labour, taking on the so-called 3Ds physically interact with humans in a shared of manufacturing—work that is dirty, workspace, enable automakers to react to an dangerous and dull industry increasingly driven by consumer • Indeed, the much-anticipated lights-out demands for more customisable vehicles. factory—an entirely automated assembly Global robotics manufacturers have line—may never be fully realised in the facilitated this evolution by developing automotive industry. Tesla was the latest innovative cobot solutions, from safe cautionary tale, with over-automation partly assembly line assistants to inspection drones responsible for Model 3 production delays, and wearable ‘exoskeletons’ and some automakers—such as Toyota—have • The use of robotics for in-plant logistics could not shied away from de-automating certain be the key to tackling increasingly unique processes

iii Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing How robots may help automakers finally realise Industry 4.0

To succeed in the face of consumer expectations, declining car sales, and uncertainty over EV adoption, automakers must embrace flexible manufacturing and design, writes Michelle Hill

utomakers today need to create production Alines elastic enough to switch from making sedans one day to sport-utility vehicles and electric cars the next. The days of plants dedicated to one product are waning, and While it may not always be normalcy for the automotive industry will be “the answer to the challenges defined by uncertainty and frequent change for the foreseeable future. facing automakers, there is

Amid this transformation, one of the no question that robots are industry’s biggest helpers is likely to be pivotal in the automotive robotic technology, and its expanding capacity to collect, interpret, and act upon industry’s eﬀorts to reems of real-time data. As the technology introduce ﬂexibility and and expertise evolves to produce manufacturing and assembly robots that are agility into its production lighter, more agile and precise than ever before, they are more frequently found routine working side by side with humans and other robots, taking over repetitive tasks or assisting with logistics and materials handling. In fact, one of the most fruitful automakers the kind of flexibility necessary to areas to automate is logistics, including introduce new models or to switch models with unloading trucks, commissioning and a minimum of down time and a maximum of selecting parts, the transportation of parts, value-added work. A growing percentage of and the collection of bins and containers. factory robots can be redeployed today after simple reprogramming. Like their human No longer the monuments to over-engineering counterparts, many have the capacity to ‘learn’ and complexity that they once were, the latest on the job, and to move from task to task on robotic technologies increasingly offer their own, in some cases.

Research by Automotive World 1 Special report: A fresh look at robots in vehicle manufacturing

Driverless bots

Autonomous mobile robots (AMRs) are prime examples of the new autonomy that bots are demonstrating within the plant. AMRs can Autonomous mobile robots navigate their way through a warehouse, “ unload a truck, or move products to the point (AMRs) are prime of use or warehouse space, relying on elaborate sensors and their capacity to learn from examples of the new humans. They allow producers to circumvent autonomy that bots are the hurry-up-and-wait mentality of many assembly lines and reserve their human demonstrating within the workforce for more value-added tasks. plant. AMRs can navigate Manufacturing operations are moving toward their way through a incorporating more of these portable, human- compatible automation systems, looking to warehouse, unload a truck, create a balance between worker and robot rather than replace one with another. With or move products to the artificial intelligence (AI) and other technological point of use or warehouse advancements, robots are able to perform tasks that previously only human eyes and minds space, relying on elaborate could handle. It’s about building an integrated smart automation architecture that can adapt to sensors and their capacity an automaker’s entire portfolio and often to learn from humans supports a system of design that stresses the need for a degree of interchangeability of parts and increased collaboration through worker teams rather than production lines. With the bodies on the same line. This gets harder and right integration of automation, people, and harder to achieve as the complexity of vehicle common processes, a team on the line can just technology increases. Especially in the United as easily put together sedans, SUVs, or even EVs. States, the drive toward customisation requires plants to be quite agile at providing various Humans and robots need to be prepared to options on different cars and switching perform a variety of tasks at each station, and production priorities as an automaker’s plant to produce several different vehicles and car strategy changes.

“A growing percentage of factory robots can be redeployed today after simple reprogramming. Like their human counterparts, many have the capacity to ‘learn’ on the job, and to move from task to task on their own, in some cases

2 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

“Systems, like cobots and exoskeletons allow workers to stay on the job longer by taking over repetitive tasks that often represent safety hazards for humans, or providing workers with a little extra ‘machine muscle’ that helps prevent on-the-job injuries

Surprise allies growing automotive Internet of Things—about to be amplified with the development of 5G wireless technology—helps to prevent the siloed Systems, like collaborative robots (cobots) and mentality that can undermine a car exoskeletons allow workers to stay on the job manufacturer’s ability to turn on a dime to longer by taking over repetitive tasks that often better reflect consumer preferences and public represent safety hazards for humans, or mandates. providing workers with a little extra ‘machine muscle’ that helps prevent on-the-job injuries. As the workforce ages, these supports will become increasingly useful, and the increasing ability of automakers to successfully integrate them into production may be a gauge of With artiﬁcial intelligence gradual worker acceptance and even “ appreciation of some of the benefits that (AI) and other technological automation affords. advancements, robots are Perhaps surprising to automakers, cobot able to perform tasks that strategy also provides more flexibility than full automation, and improves the industry’s ability previously only human eyes to re-use and re-deploy assets at a lower capital and minds could handle expenditure cost. The latest robots can be pieced together with plug-and-play modules that can be reconfigured as needed for added agility and flexibility. Ultimately, many assembly activities are simply too difficult to Robot technology is no longer a nice-to-try automate, or the automation would be too experiment for pioneering automakers. While it costly. may not always be the answer to the challenges facing automakers, there is no question that More than anything, robots afford automakers robots are pivotal in the automotive industry’s the ability to use the terabytes of data efforts to introduce flexibility and agility into its generated regularly at their factories, or by the production routine. army of vehicles on the road. The new capacity of robots to collaborate with other robots—tech talking to tech—tears down walls between Michelle Hill is a vice president with Oliver departments. The connectivity among the Wyman’s automotive practice

Research by Automotive World 3 Special report: A fresh look at robots in vehicle manufacturing

Automaker snapshot: who's doing what with robots

Megan Lampinen takes a look at how some of the leading automakers are deploying manufacturing robots today

he factory of the future is one in which Trobots are set to play a starring role. They promise considerable improvements across a number of key metrics, from production volumes and product quality to worker safety We can have operators and job satisfaction. Automakers are already “working in closer proximity well on their way to achieving this future vision today. to the robots, and in some instances in unison with Dagenham's cobots them Industrial robot installations in the UK have been rising for three consecutive years and now number about 2,300 units. A recent report by market research institute automatica found that "We can have operators working in closer UK employees are particularly keen for robots proximity to the robots, and in some instances in to take over the unhealthy (83%), the dangerous unison with them," explained Jack Spurling, (77%) and the monotonous (72%) jobs. Emerging Technology Engineer at Dagenham. "It has proven a more cost-effective solution for our Ford's Dagenham Engine Plant in England has installs and gives us the extra flexibility we need been using a number of robots to help for our frequently changing builds. We have assemble engines. Cobots from Universal been able to re-utilise labour on more complex Robots are currently deployed to carry out jobs and have taken some of our less ergonomic various operations, including excess sealant applications away from manual work." removal, vision inspection with a camera, hardware installation in place of manual hand BMW—two decades and starts, the final rundown of glow plugs, timing pin pull and dowel insertion. Specifically, the counting plant relies on the UR10 model, a collaborative industrial robot arm designed BMW has been operating highly automated for bigger tasks that demand precision and press shops, body shops and paint shops for reliability. This particular unit can be used to more than two decades. More recent years automate processes with payloads that weigh have seen the automaker bring in collaborative up to 10kg (22 lbs) lightweight robots. The earliest of these units

4 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

Our goal at the BMW Group is not to replace human labour “with automation. With a clear focus on effectiveness, we strive to combine both, based on the specific strengths of humans and robots

was commissioned in 2013 at the BMW Group unit at its Regensburg facility, a worker guides a Spartanburg plant in the US. Affectionately large industrial robot to the screw bonding known as 'Miss Charlotte' by the line crew, this station. A laser-based scanner system supports robot is still in use mounting sound insulation the process of placing the industrial robot; the panels to doors. exact position is determined by the trained worker. "As always, safety is the top priority," Today, around 100 lightweight robots are in use insisted Burseg. "Should a person get too close across BMW Group facilities, handling those to the robot while it gets into position, state-of- tasks that would be physically strenuous for the-art safety technology slows down the workers or pose particular challenges due to the movement of the robot arm, to a total standstill high level of precision required and the if needed, thus avoiding any potential harm to repetitiveness involved. "The allocation of roles the human. Due to the high torque forces between humans and available tools is clear: required in this operation, the task could not be their high level of expertise, creative and assigned to a lightweight, collaborative robot." cognitive skills make humans ideally suited for tasks that focus on actual value creation, specific Volvo Ghent: home of the precision work and quality management," explained Lukas Burseg, Specialist—Sensitive Beast Lightweight Robotics, Human Robot Collaboration and Mobile Robotics. "Assistance Volvo Cars' Ghent installed 363 new robots in systems, on the other hand, support people in preparation for the SC40, its first small SUV carrying out strenuous and repetitive tasks that and the first model on its new modular small constitute a stereotypical strain." car platform. One of these robots stands out from the others. Nicknamed 'the Beast' by Burseg noted that lightweight robots do not Ghent employees, this particular unit is used to require any additional fixed points and are lift car bodies to a conveyor belt close to the relatively flexible in where they can be applied. ceiling of the plant. "The Beast is the only such "Moreover, they can work together in the same robot in the Benelux region," a spokesman space with people," he added. "As a rule, the observed. It has a reach of 4.2 metres and a implementation of assistance systems is about payload of 550kg. finding reasonable solutions for the respective purpose, while always keeping in mind the Today, Ghent deploys 1,000 robots, with 900 specific benefit to be achieved." in the bodyshop alone. These are used mainly for spotwelding but also for handling and BMW is also exploring direct human-machine mounting, nutwelding, bolting, dispensing cooperation with conventional, large-scale glue, laserwelding, arcwelding, measuring, industrial robots. In the transmission assembly nutrunning and studwelding. The paintshop

Research by Automotive World 5 Special report: A fresh look at robots in vehicle manufacturing

“Their high level of expertise, creative and cognitive skills make humans ideally suited for tasks that focus on actual value creation, speciﬁc precision work and quality management

has 70 robots to help with paintbrushing and in paintbrushing, sealing and final assembly sealing, while the final assembly operations use have all resulted in better quality and 24, mostly for handling and mounting, but also ergonomic factors. sealing and laserwelding. Trucks need robots, too The units, provided from leading suppliers including ABB, Comau and Dürr, have improved in performance over the past years. Robots are also revolutionising truck "The main advances have been in the accuracy production. The Daimler KamAZ Rus joint of the robots, as well as the speed at which they venture recently opened a highly automated can operate, and their safety," Automotive truck cabin production facility in Naberezhnye World heard. Chelny. Stefan Buchner, Head of Mercedes- Benz Trucks worldwide, heralded it as "one of Their impact has been notable. Automating the most innovative facilities in the Russian spotwelding tasks and handling and mounting automotive sector." jobs have helped to reduce production times and improve ergonomics and accuracy. The plant has deployed more than 120 robots Deploying robots on laserwelding has from Kuka and Dürr, which can perform contributing to improved safety, while those multiple tasks. "In general, our robots are designed to load parts, to weld, to apply sealing and gluing material, to place bolts, to paint, to open doors in the paint shop, and to perform measurements in the body shop," a spokesman explained. "The main application for these robots is in the body shop, where they can precisely manufacture the cab design and ensure best quality. They allow us to reach the “The main advances have highest level of sustainable quality and efficient been in the accuracy of the production, especially in the paint shop." robots, as well as the speed Spotlight on Audi at which they can operate, The body shop is also the focus of Audi's and their safety industrial robots. "Here, the level of automation is highest within car production," explained Thomas Seitz, a robotics expert at Audi. "Basically, these robots are used for handling

6 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

“Robots have a very high repeat accuracy. In general, they are very good in supporting people and relieving them from heavy physical work or monotonous tasks—a great advantage considering the demographic change car body parts, joining technologies and inline- Impact on workers measuring systems." The benefits are numerous. "By using robot-based applications, it is possible to shorten cycle time and to raise volumes," he Many major manufacturing regions, including added. "Another advantage is that heavy and Audi's home market of Germany, are facing a sharp-edged parts can be handled easily." dwindling workforce. Replacing some of those workers, or making the duties of others lighter, Audi uses industrial robots from Kuka, ABB and through robotics is one option for Fanuc in its series production. For collaborative manufacturers. In theory, automation, and robotics, it uses systems from Kuka, Fanuc and robots in particular, could help fewer people Universal Robots. These developers have been work more productively and more safely. But actively refining and expanding their system does this mean they pose a threat to jobs? capabilities, and nothing stands still for long. "We have seen major advances in this area, "Our goal at the BMW Group is not to replace including safer robots, sensor-based human labour with automation," stated Burseg. applications and improved performance in "With a clear focus on effectiveness, we strive accuracy and stiffness of the robot," Seitz to combine both, based on the specific noted. "Due to these advances, it is possible to strengths of humans and robots. Rather than reach a much higher level of personal security." often inflexible, ‘pure’ automation, the combination of human labour with assisting At its Ingolstadt plant, Audi deploys collaborative automation solutions makes the production robots alongside humans to help assemble system leaner and more adaptable. While vehicles. The robots assist specifically with humans are extraordinarily versatile in adhesive application, during which a human is operating in changing or highly complex aided by a robotic arm to install the carbon-fibre environments, the robot co-worker is able to reinforced polymer roof on Audi RS5 models. perform repetitive and strenuous parts of the While the human worker places the roof on a process, thereby increasing quality and human spinning table, the robot applies the precise ergonomics." amount of adhesive to specific areas. Once the robot indicates it is finished, the human installs Audi echoed this sentiment, noting the the roof on the car. "Robots have a very high superiority of humans over robots when it repeat accuracy," pointed out Seitz. "In general, comes to cognitive functions. "Humans are they are very good in supporting people and much more flexible and can react very quickly relieving them from heavy physical work or to unexpected incidents," observed Seitz. monotonous tasks—a great advantage "There will never be a factory without humans considering the demographic change," said Seitz. at Audi."

Research by Automotive World 7 Special report: A fresh look at robots in vehicle manufacturing

Forget the lights-out factory: humans will remain essential for vehicle manufacturing

Robots are undoubtedly getting smarter, and we can expect more automation, but human input will remain critical in the manufacturing process. By Xavier Boucherat

t is not often we see one of modern behind the delays in hitting the much-vaunted Iindustry’s most polarising forces climb production target of 5,000 vehicles a week, down from one of their stated positions, but and for a while it was not clear when the that is exactly what Elon Musk did in the wake mass-manufactured gambit’s stay in of a damaging attempt to introduce further “production hell” would end. At one point, automation on the Tesla Fremont factory’s Musk was referencing former GM Chief Model 3 assembly line. Musk admitted that Executive Roger Smith’s dream of a ‘lights-out excessive automation was part of what lay factory’. Later, he would concede on Twitter, “Humans are actually pretty underrated”.

This might have been news to Musk, but some automakers have known this for some time, particularly when it comes to the final assembly Consumer demand will play stage of vehicle production. Toyota has gone so far as to de-automate steps in its manufacturing “an important role alongside process, reintroducing humans along the length of the line, particularly for the purposes other factors—like the of quality checking. changing skill set of the In one example, as reported by Roland future workforce—in Berger, the company took steps to de- determining which automate a welding operation being performed on the base of its Land Cruiser manufacturers might de- model. Performed by a robot, the weld was too wide and held defects. Done manually, automate and which might workers were able to determine where the scale up their automation weld could be thinned. Then, workers were able to teach the machines themselves how best to perform the task, before the job was re-automated.

8 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

AI and machine learning are improving, but technology that can “work alongside humans is becoming especially popular, as it can merge superior human decision-making with a robot’s precision and strength

Equilibrium Currently, no automaker is seriously—or at least, publicly—entertaining the notion of a completely lights-out factory. Along with the The keyword is balance, with doubts being cast difficulty of automating certain production on earlier expectations of fully automated process, there is the question of roles such as factories. A major concern is the reliance on maintenance and planning, which are likely to automation, and what happens in the event of always require highly skilled human labour. failure; should something go wrong with the automated technology, this could lead to costly Crucial is the issue of Design for Manufacture line stoppages, impacting efficiency and and Assembly (DFMA), the twin methodologies quality. Questions also need to be asked about which determine the ease with which parts can the value of investing heavily in the be manufactured, and then assembled—and development of automation to carry out considerable differences still exist in the way complex tasks that humans can already do. automakers approach DFMA and how they might introduce automation. Indeed, Michael Woodward, UK Automotive Partner at Deloitte, believes that humans remain “Walk around any car plant, and most of the inherently better at certain tasks. The ability to work is done by robots, from when the vehicle adapt to different situations in particular means comes in as a body-in-white, through the paint people continue to have a significant advantage shop, right the way through to final over the majority of ‘shop floor’ robots. inspection,” points out Nick Harrison, a Partner However, he adds, the example of Toyota does at KPMG. “But all through the assembly not mean that every automaker should be process, there is a human presence to monitor rushing to dismantle their robots: no single and expedite any issues faced, particularly in solution will work for every vehicle the Manufacturing Execution System (MES).” manufacturer, he says, on account of the automotive industry’s diverse demographic. However, Deloitte’s Woodward stresses that the idealism behind it should not be written off, Customers purchasing luxury cars, for example, as the benefits are substantial. Many industries will expect that their vehicles are handmade. are working towards it, and those that pull it off Manufacturers must identify which processes can will win big. “They bring huge benefits,” he be achieved with a robot, and which cannot, in says, “including more efficient energy use, a order to improve productivity and avoid wasteful reduction of accidents, and improved investments in robots ill-equipped for the task. productivity.”

“Consumer demand will therefore play an Whether certain parts of a factory could go important role alongside other factors—like the dark is a possibility that some automakers changing skill set of the future workforce—in might be entertaining, with sensors becoming determining which manufacturers might de- increasingly cheap and AI becoming ever automate and which might scale up their more capable. Harrison adds that whatever automation,” he says. the case, more automation should certainly

Research by Automotive World 9 Special report: A fresh look at robots in vehicle manufacturing

be expected, particularly with vehicle Advances in AGV technology have been platform complexity reducing as a pushed by a number of automakers; also consequence of electrification. being explored is the use of drone technology; the potential for aerial drones to Old tech, updated be used in factories to perform stock checks and quality checks on parts has already been floated, but they could also be used by New robotic technologies are also appearing in factory managers to inspect robots in supporting manufacturing roles, and dangerous or hard-to-reach areas of the technological advances have given fresh life factory, such as in the body shop. and new purpose to decades-old technologies; one such technology making significant strides is the automated guided vehicle (AGV), used at Your new colleagues a fast-growing rate primarily in logistics and material handling to spare humans from Collaborative robots, or cobots, play an particularly arduous and mundane tasks. Once important role when discussing the human- a simple vehicle following yellow lines painted robot mix found in tomorrow’s car factories, on the factory floor, a modern AGV can now assisting workers with heavy lifting or dull and calculate and recalculate routes and avoid repetitive tasks, and helping with accuracy and obstructions, and even can operate in the dark. quality. They also help to lighten the load, an Grand View Research expects the global important factor in a number of markets facing Automated Guided Vehicle (AGV) market, the challenge of ageing. Universal Robots is the which it valued at just shy of US$2.5bn in 2018 market leader in cobots across all industries, across all industries, to grow at a CAGR of 15.8% with a considerable number of other from 2019 to 2025. manufacturers seeking to gain market share.

Seegrid is one of the companies making moves In 2018, a Loup Ventures report forecast global in the AGV segment. The Pittsburgh- robotics spending reaching US$13bn in 2025, headquartered company lists JLR and BMW with the share of collaborative robots growing among its customers, and claims its Vision from 3% currently to 34% in 2025. Another Guided Vehicles (VGV) have performed over study, by Interact Analysis, predicts a sharp rise 1.9 million miles of operations in the real in the already fast-growing cobot market, with world. The important benefit of its new revenues reaching US$7.5bn by 2027, when generation vehicles, it says, is the ability of cobots will account for almost 30% of the customers to easily reconfigure routes industrial robot market. The numbers may vary, through a warehouse, rather than needing but the order of magnitude is clear: expect specialist help. considerable growth in the cobot market.

Woodward adds that a further benefit of cobots will be the synthesis of man and machine’s superior qualities. AI and machine learning are improving, he says, but No single solution will technology that can work alongside humans is “work for every vehicle becoming especially popular, as it can merge superior human decision-making with a manufacturer, on account robot’s precision and strength. This is surely of the automotive industry’s the ideal scenario for manufacturers, particularly as increasing customisation makes diverse demographic more diverse demands of factories. But cobots will first need to overcome their current limitations, including their safe functioning at full speed in proximity to humans.

10 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing Automakers need robots that deliver universal solutions and flexibility

The automotive industry is in flux, says ABB Robotics, and the manufacturing process needs to become more adaptable in response. By Betti Hunter

ollaboration between humans and robots Chas completely revolutionised the manufacturing landscape. 2019 research by the Federal Reserve Bank of St Louis found If you look at the body-shop that manufacturing output has achieved “as an example, the number record highs in the most recent quarter, with US manufacturers now producing 47% more of robots deployed in a than they did a decade ago. Now more than ever, new generations of robots make it manufacturing line has possible for machines and humans to work alongside each other. doubled over the last 10 years, increasing ﬂexibility, The automotive industry is weathering changes good and bad, as shifting mobility quality and ultimately trends force automakers to re-evaluate their throughput operations. But although global car sales have remained broadly flat over the past couple of years, the process of vehicle manufacturing has become increasingly fascinating, creating Such progress has led to a rapid increase in more opportunities for innovation and productivity across the industry, across the development. board, from the press shop through to final assembly. “If you look at the body-shop as an According to the International Federation of example, the number of robots deployed in a Robotics, statistics for world-wide shipments manufacturing line has doubled over the last of robotics reveal monumental growth within ten years, increasing flexibility, quality and the industry. In 2013, world-wide shipments of ultimately throughput,” Larsson told robots totalled 178,000; in 2018 the number Automotive World . was 384,000. “That’s a clear sign that robot automation is in a tremendous growth mode, This rise in the development and application of particularly in the automotive industry,” said robot automation has been driven by the Michael Larsson, Global Head of Robot growing availability of new materials, low cost Systems at ABB Robotics. sensors and open software architectures. Today

Research by Automotive World 11 Special report: A fresh look at robots in vehicle manufacturing

New product lines can be installed faster and ramped up to full “speed without surprises during commissioning—a critical competency for manufacturers with today’s mass customisation and shorter product life cycles robots that ‘see’ and ‘feel’ can work in a to better understand production bottlenecks, collaborative setting alongside operators in individual asset performance and adjust automotive factories, making it possible for capacity to better respond to changes in human workers to share their workload and customer demand.” workspace with machines. “In the past, robots were predominantly focused on the repetitive The increased availability and use of digital tasks and handling of larger components,” said simulation tools is also helping ABB’s Larsson. “Today, collaborative robots like customers. RobotStudio, ABB's simulation and ABB’s YuMi can perform vision-guided small offline programming software, is a PC-based parts assembly, such as cylinder head solution for programming, configuration and assembly, with great precision and quality.” virtual commissioning before installation which offers a complete digital replica of physical Diverse solutions assets or systems. “Manufacturers can see what’s going on in their production line, enabling them to create, simulate and test a ABB in particular has developed multiple complete robot installation in a virtual 3D machines and systems for 21st century environment without having to disturb automotive production. “Our ModulFlex operations,” explained Larsson. “New product system allows up to six models to be produced lines can be installed faster and ramped up to on the same line, reducing capital that would full speed without surprises during be expended for dedicated systems for multiple commissioning—a critical competency for variants, in combination with intra-logistics and manufacturers with today’s mass customisation kitting solutions where ABB can move material and shorter product life cycles.” off the line creating additional efficiencies in floor layout,” explained Larsson. Flexibility is needed The company has launched its visual-servo technology to assist operators with heavy lifting Following and responding to consumer trends and precise fitting in final assembly operations. is now more important for automakers and Its Connected Services platform, which helps suppliers hoping to survive the industry’s end users to collect and analyse real-time current seismic shifts. The automotive industry information from fleets of robots, currently is undergoing changes in terms of market monitors the performance of more than 7,000 dynamics, with consumers looking for more robots in over 750 factories worldwide. individualisation and shorter delivery times.

Solutions also extend beyond the factory floor. At the same time, explained Larsson, “Beyond the robot we are also working with Millennials are altering the mindset on car our customers to deploy our portfolio of digital ownership, looking at car-sharing and ride- solutions to the cell and line-level,” said sharing services as viable alternatives, and Larsson. “The ABB Ability platform makes it geographical shifts in demand with more cars possible to acquire and analyse plant level being sold in the Asia-Pacific region is creating information, enhancing our customers’ ability the need for a different manufacturing

12 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

footprint. These trends necessarily impact all aspects of the manufacturing process, which in turn is driving the development of ever more Both automakers and complex and competent machine systems. “suppliers need a much “Customers require solutions to increase their flexibility,” said Larsson. “One of the more more dynamic delivery obvious trends is digitalisation and Industry 4.0, model with shorter where connected robots and manufacturing equipment provide automakers and Tier 1 deployment cycles, better suppliers an entirely new set of tools to customer responsiveness, understand, monitor and improve throughput, quality and efficiency in green-field as well as and the ability to change brown-field settings.” In the future, he continued, automated guided vehicles (AGVs) manufacturing platforms and mobile robots have the potential to change based on model success line layouts and eliminate the traditional fixed conveyor. “This gives manufacturers an opportunity to change their layout to better challenges due to changes in social accommodate part flow, and add kitting demographics. “A few countries in the Asia- processes, all aimed at helping the manufacturer Pacific region, for example, see an ageing handle logistical challenges,” he added. population where there will not be enough skilled workers in the future to support the current level Automakers are also in need of radical robotics of manufacturing,” Larsson remarked. “The need solutions to keep pace with the evolution of to continue to automate is clear.” electric vehicles (EVs) and the greater variety of models in production. The challenges In Europe and the US, he continued, the surrounding EV manufacturing are expanding increase in college education has meant a shift out from battery cell and motor production. away from vocational training that was far Increasing range is a priority, but to do this, more common in decades past, leading to a vehicles must be lighter. Manufacturers are shortfall of skilled workers in certain fields moving away from mainstream steels in favour necessary to keep productivity at current of lighter materials, such as aluminium. This levels. “This strengthens the case for increased works towards solving the weight issue but automation to help alleviate some of these means that spot welding must now be replaced challenges,” said Larsson. by bonding and riveting. According to Larsson, the adoption of digital “To respond to these challenges, both technology will continue to revolutionise how automakers and suppliers need a much more factory floors are run. This trend will continue to dynamic delivery model with shorter accelerate, creating a digital ecosystem that deployment cycles, better customer connects manufacturing equipment with edge responsiveness, and the ability to change and cloud computing and making Big Data manufacturing platforms based on model analytics a reality. Machine learning will become success,” said Larsson. ever more prevalent, with robots and equipment learning to self-adjust their performance based Universal applications on anomaly detection. Self-optimising paint atomisers, advanced vision systems, To a large extent, the industry will benefit from autonomous grasping and collision-free path facing challenges that are uniform across most planning, predictive maintenance monitoring world regions as the solutions that are developed and real-time data analysis are just some of the have the potential to be universally applied. current and future options that will rewrite the However, certain countries pose specific playbook for vehicle production going forward.

Research by Automotive World 13 Special report: A fresh look at robots in vehicle manufacturing Cobots are a crucial step on the path to AI-driven automation

Collaborative robots will be an automotive industry game- changer, but are not endgame technologies in and of themselves. By Betti Hunter

he automotive industry has long led the factories would have become obsolete long ago if Tway in terms of robotic manufacturing, and it were not for the rise of new, innovative robotic according to the International Federation of technology. “Automation is necessary for safety, Robotics (IFR) remains the largest adopter of quality and productivity," he told Built In robotics technology globally. Today, robots are magazine. And as automotive trends continue to an essential factor for automakers seeking to evolve, robotics manufacturers are responding to retain a competitive edge; a 2018 IFR report their client’s needs by designing ever smarter showed that the industry represented a 33% machines that work with, instead of for, their share of worldwide robotics sales as human counterparts. manufacturers work to diversify their portfolios and meet the demands of an ever- “Collaborative robots—or cobots—have many changing mobility landscape. huge benefits,” said Duilio Amico, Network Development Director of robotics and According to Dr Jay Baron, former Chief automation products at automation company Executive of Ann Arbor, Michigan-based Center Comau. “The foremost is combining human for Automotive Research (CAR), many automaker capabilities and adaptability to manufacture with machine strength and repeatability. They offer the best of both worlds.” ‘Almost human’ Cobots fuse the intelligence Until recently, robots worked in isolation. The “and dexterity of a human large, heavy and often dangerous machines were kept separate from workers, often in caged being with the strength areas, to minimise workplace incidents. But this and the repeatability of factory layout is changing fast. Cobots, defined as a robot intended to physically interact with a machine humans in a shared workspace, are progressively being introduced as a way to offer more accuracy, safety and productivity within the manufacturing process.

14 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

“Cobots normally work at a very low speed as compared to traditional robots, and have sensors and torque control to detect proximity to a human, leading them to slow down or stop if they are at risk of hitting a person

“There are various technologies in collaboration Comau has already made sizeable inroads into robotics which can be clustered in a couple of developing and mass producing cobot solutions. major groups, chief among them being torque The company launched its high payload control,” Amico told Automotive World . “Cobots Advanced Use Robotic Arm (AURA) in 2016. normally work at a very low speed as compared Described as “almost human” with regards to its to traditional robots, and have sensors and sensitivity levels and inspired by human torque control to detect proximity to a human, interactions, it offers adjustable collaborative leading them to slow down or stop if they are at and non-collaborative modes depending on the risk of hitting a person.” required use case. Laser scanners and a vision system enable AURA to identify the proximity of Furthermore, in an industry increasingly driven a worker, predict their motions, and adjust its by consumer demands for more customisable trajectory accordingly, allowing it to directly vehicles, flexibility is key to coping with support humans as they work. diminishing batch production sizes. “Mass customisation is the emerging megatrend that is In 2018, Comau followed up AURA with MATE, the biggest challenge for the automotive a non-robotic, spring-based wearable business,” Amico said. “This is one of the exoskeleton designed to provide consistent and biggest pushes we have as system integrators to advanced movement assistance during comply with our customers’ needs.” repetitive tasks. The company claims that MATE reduces shoulder muscle activity for A growing market some muscles by up to 50%. “There is a lot of research in this area,” said According to a report by Research and Markets, Amico, “and Comau believes that will be the the global cobot market is expected to be worth next frontier and the next challenge for almost US$9bn by 2025—a growth rate of nearly collaboration robotics. If we have the capability 47% from 2018. The term cobot covers a wide to develop a skin or a suit that can be applied to array of robotics solutions, from safe assembly industrial robots, we can guarantee a much line assistants to inspection drones and wearable more affordable collaborative robotic product ‘exoskeleton’ robots for repetitive to our customers, and also considerable manufacturing tasks. In 2018, Dan Grieshaber, flexibility. Industrial equipment that is General Motor’s Global Director of already installed can be upgraded or Manufacturing Engineering Integration, called transformed into a cobot with relative ease, the fast-evolving cobot spectrum a “fundamental without getting into purchasing and installing game-changer” for the automotive industry. a completely new robot.”

Research by Automotive World 15 Special report: A fresh look at robots in vehicle manufacturing

“Industrial equipment that is already installed can be upgraded or transformed into a cobot with relative ease, without getting into purchasing and installing a completely new robot

Steps towards AI capitalise on uniquely human strengths that can be replicated and applied across the world regardless of cultural differences. Cobots themselves, however, are not an endgame technology. “Considering that “Humans have a manual dexterity that is as yet artificial intelligence (AI) has not yet developed unreachable by machines, so Comau has to the extent that it can mimic a human being, launched a device called Virgil, which guides collaborative robots are a stepping stone human hands into diverse manufacturing solution,” Amico explained. Many in the operations with lights and symbols,” explained industry are confused about AI’s current and Amico. “It also tells the on-the-spot operator future potential, he continued, often failing to how to cope with different manufacturing differentiate between as-yet unavailable AI processes, thus minimising much of the systems that can make decisions and learn and learning process and faults or defects in grow autonomously, and the more realistic manufacturing, and helps to manage cultural near-term prospect of machine learning. diversity by standardising procedures.” Cobots are a crucial transitional step towards more advanced automation, with some models The universality of cobot models does not just such as Audi’s Walt already able to utilise deep have the potential to create a global production learning to recognise and communicate with standard; it could also help to level the playing co-workers via gestures and learn new tasks. field between automakers and suppliers of all sizes as the automotive industry remains in flux. “This is something that is really achievable and currently working in factories,” Amico added. “Cobots use less space than a traditional “Without going into hyperspace and science robot,” said Amico. “This sounds trivial, but it fiction, cobots fuse the intelligence and is a very important point.” Most conventional dexterity of a human being with the strength robots have a large factory floor footprint due and the repeatability of a machine.” to the inaccessible cells they are housed within. “These cells must encompass the entire Levelling the field working area of the robot, with extra space and security locks,” Amico continued. “If you Comau’s preferred term for this meeting of eliminate everything about that, a lot of space is worlds is ‘humanufacturing’, a term coined by saved. Industrial space is a scarce resource, so the company itself. “This term syncs very well if we can create a machine that performs the with our current vision, without looking same functions with a reduced spatial decades ahead,” said Amico. “We need to footprint, it offers a huge benefit to provide practical solutions to our customers manufacturers. Our customers have judged this here and now.” For the foreseeable future, the as one of the major elements in the economy of company is focusing on creating products that their production.”

16 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing Automotive stamping is an increasingly sophisticated business

More robots are being introduced onto press lines, but not without good reason: efficiency, quality and uptime are paramount at this stage of vehicle production. By Xavier Boucherat

fter the production of steel and manufacturing trends and greater automotive Aaluminium sheets and their subsequent trends? The sheer amount of energy and force cutting, stamping is among the initial behind metal stamping brings further processes in vehicle production, a vitally considerations for manufacturers, particularly important phase that has deep implications at a time when automakers need to reduce for final build quality. It begs the question: their carbon footprint. what is driving the evolution of stamping technology, and how is it being affected by Unsurprisingly, stamping technology companies such as Schuler are embracing the principles of Industry 4.0. In particular, Schuler is exploring the potential for improvement of its machines through digitisation, which it believes will help deliver the next generation of press lines that will rely So far, the focus has been on robotics to ensure the smooth and efficient “ flow of materials. on the hardware, which we are able to greatly improve “So far,” said a spokesperson for the company, “the focus has been on the through developments hardware, which we are able to greatly such as the ServoDirect improve through developments such as the ServoDirect technology. In this way, we have technology. In this way, we also increased machine availability.” Servo refers to servomechanism, motors used in have also increased applications where precise motion is machine availability required, such as handling of parts and materials in a press line. Servos produce motion in response to commands, and then regulate and correct errors in the motion by responding to feedback.

Research by Automotive World 17 Special report: A fresh look at robots in vehicle manufacturing

“We have reached a limit. The possibilities of mechanics are largely exhausted in conventional mechanical engineering, and further optimisations are very time-consuming. Digitisation is an instrument to exploit new potential

“However,” the spokesperson adds, “we have would grant the supplier invaluable insight reached a limit here. The possibilities of that it would carry forward into future mechanics are largely exhausted in development. “It will enable us to raise conventional mechanical engineering, and production efficiency and digitalisation of further optimisations are very time- important process steps in car manufacturing consuming. Digitisation is an instrument to to a new level for forming technology,” he exploit new potential, and we also provide said. “Ultimately, other customers of Schuler our customers with auxiliary tools for further will also benefit from the project.” optimisation.” Whilst Porsche explore options, Audi has also been investigating potential for smarter Smart Press stamping. Its main plant in Ingolstadt uses artificial intelligence and machine learning in The ‘Smart Press Shop’ has emerged as a quality check techniques on stamped metal consequence, an intelligent and fully networked parts to detect cracks, marks and other press line which the company hopes will be more reliable, more efficient, and greener. “It will be possible to accurately predict potential downtime with the aid of sophisticated sensors, actuators, and the data they collect,” explained the spokesperson, “and avert this downtime well in advance. This helps to ensure our customers’ productivity and increase the quality It will be possible to of the parts they produce, while also reducing “ accurately predict potential energy requirements.” downtime with the aid The company has entered into a joint venture of sophisticated sensors, with Porsche and has chosen Halle an der Saale, Germany, as the site of a new press actuators, and the data shop which will serve the nearby Porsche Leipzig plant. Smart Press Shop GmbH & Co. they collect will invest over €100m (US$113m) into the project. Schuler Chief Executive Domenico Iacovelli said that whilst co-operation with Porsche was a priority, the Smart Press JV

18 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

“In the past, just eight robots were running in a simple press line. The trend continues to rise; however, we try to integrate functions to limit the number of robots

shortcomings. This improves on previous This is part of a trend which has introduced techniques relying on cameras, which can more and more robots into the press, to the often produce false positives. point where many press lines are effectively 100% automated. However, there is no At the heart of the digital toolkit, says automation for automation’s sake. Robots Schuler, is its Machine Monitoring System. introduce cost, and so their number must be This is used to collect, analyse, store and kept to a minimum without impacting quality evaluate production conditions within a and efficiency. “In the past, just eight robots press. Of great importance is its were running in a simple press line,” said a compatibility: it works with both new and spokesperson. “The trend continues to rise; existing machinery, and can be operated by however, we try to integrate functions to customers directly on their plant equipment, limit the number of robots.” via their servers, or over their network. At some point in the future, control via the The increasingly complicated process is cloud will also become possible. But what enabled only with the appropriate tools. about the robots within the press-line that “Given the complexity of the production enable throughput? process,” he adds, “a simulation tool is a prerequisite for the smooth operation of the whole system, as well as virtual The robots are multiplying commissioning with the help of a digital twin. In addition, with our Machine Monitoring The robots used by Schuler are developed in- System, Schuler can observe the toolings of house, as they offer speed and efficiency not the robots.” available in the commercial robot market. The automation systems in modern presses Demystifying the process and keeping will generally use seven crossbar feeders, things transparent for customers is an robotic arms which transfer parts from die to important part of Schuler’s Industry 4.0 die with intermediate deposit stations. Seven- strategy, as this will improve the uptime on axis freedom gives them the flexibility to its systems. “Industry 4.0 is also about work in the tight confines of the press. One or making this know-how accessible to all two additional robots are used to centre employees, and not limiting it to a few blanks, ten are used to stack parts and eight people,” said the company. “Networking are used in the automatic quality control offers the opportunity to distribute the process, making a total of 27 robots. knowledge to an entire company.”

Research by Automotive World 19 Special report: A fresh look at robots in vehicle manufacturing

Cost and impact: assembly line robots hit the sweet spot

When it comes to financial investment and productivity impact, assembly line automation strikes an attractive balance. By Megan Lampinen

he automotive industry has emerged as a Tpioneer in adopting smart manufacturing technologies. ABI Research estimates that the industry in general has automated around 50% There is a disruptive of its operations, compared to a 20-30% “change coming with automation rate for most other industries. Automation takes many forms, but vehicle and manufacturing, and component assembly line operations represent a particularly promising application area. collaborative robots ﬁt right

Work on the assembly line regularly requires into that. We are starting to speed and precision in repetitive tasks where see people look at robotics mistakes cost both time and money. Even the most skilled workers grow tired or distracted, as a tool to make their and eliminating human error completely is a big ask. This is where robots could make a big tasks simpler impact. Tiredness and distraction do not affect robots and, in many cases, they can operate faster and with greater precision than a human. worker is shown controlling four robots in a For manufacturers, that translates into fewer cradle. He can pull the cradle underneath a production bottlenecks, increased capacity, vehicle on the production line, and six-axis improved product quality and lower warranty robots reach up and tighten bolts into the costs. For workers, it could mean relief from undertray of the vehicle. "In the past, this dirty, difficult and dangerous tasks. would have been two guys with two bolt runners," explained Mark Gray, Sales Manager for Universal Robots’ UK operations. "There Automaker applications would be people crawling about underneath vehicles, and the potential risks that come with Audi has been deploying and evaluating robots that. Now it is just one guy operating four in numerous manufacturing applications, robots. This approach increases productivity including assembly. In one video, a single and also makes it safer for humans."

20 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

The robots themselves use the tools—the bolt runners, the “screw inserters, the glue guns, the sealant guns— with people working alongside, putting the parts onto the assembly and letting the robots do the repetitive tasks

The robots in this application were provided by require less space in the factory. Because of Denmark-based Universal Robots, which also that, Nissan is considering robotic applications provides similar robots to PSA and Renault in in additional manufacturing areas. France. These are collaborative robots, or cobots, which work alongside humans. "There "Automotive players frequently use is a disruptive change coming with collaborative robots to help with sub- manufacturing, and collaborative robots fit assemblies," noted Gray. "The robots themselves right into that," Gray told Automotive World . use the tools—the bolt runners, the screw "We are starting to see people look at robotics inserters, the glue guns, the sealant guns—with as a tool to make their tasks simpler." people working alongside, putting the parts onto the assembly and letting the robots do the In Japan, Nissan has been using UR10 robots in repetitive tasks. We are seeing more and more the assembly processes at its Yokohama plant. of this, where the robot is almost used as a tool. They are deployed to assist with loosening bolts It's like an extra pair of hands." on engine cam brackets and the installation of engine intake manifolds. The main challenge Even in India, a country known for its cheap Nissan wanted to address was takt time manual labour and low levels of automation, overruns, which happened every time there interest is growing. Motorcycle manufacturer was a variation in production volumes. As it Bajaj Auto was one of the first to make an turns out, the use of robots not only resolved investment in assembly line cobots. Today it the takt time problem but also reduced the deploys numerous 5kg robots for such tasks as physical strain for workers. This was heavy welding, deburring, machine tending, bolt work—the intake manifold alone weighs 4kg, tightening and sealant application. Bajaj was so and workers handle them all shift. The fact that impressed with the impact of these robots that the robot passed the part to the worker it began making them itself. Several years ago, emerged as a significant added benefit. it signed an agreement with Universal Robots to assemble its cobots in India, using software and And notably, these robots require no safety electronics from Universal Robots but with fence—many others do in order to protect the localised components. Today, Bajaj-built cobots humans on the factory floor. After all, robots can be found in the assembly lines of its can move quickly and often in a way that is not facilities in Chakan, Waluj and Pantnagar, as anticipated by those nearby. However, well as in the facilities of some of its suppliers. companies have begun looking at alternative measures to cages or fences. For instance, some robots have been designed to stop The sweet spot moving before they run into a human that accidentally interrupts their path of motion, Robots come in all shapes and sizes but those and then wait until it is clear to move. As well deployed in the above examples are a world as being safer, these cage-less approaches apart from the larger industrial robots. Gray

Research by Automotive World 21 Special report: A fresh look at robots in vehicle manufacturing

regards the two industries as "completely the automotive industry will be powered by parallel streams of automation". batteries and alternative energy sources," observed John Miles, Global Business Leader— As well as benefits in terms of precision and Electric Vehicles at Rockwell Automation. speed, these sorts of systems are affordable. US- "Digitalised gigafactory operations can optimise based robot supplier Acieta points out that such their production in real time, improving off-the-shelf tools can be installed and productivity, product reliability, and quality." commissioned much quicker than special- purpose equipment. They are also easily Others have also seen fresh potential in EV reconfigured. “Assembly line robots are a low- production. "We are finding that EV technology risk investment that simultaneously satisfies the lends itself nicely to our kind of robots," said demands of manufacturing, quality and Gray. The company has provided robots for finance,” it asserts. For automakers concerned Nissan operations assembling Leaf EV battery about fluctuating demand, robots can be packs. As with the Yokohama intake manifold redeployed easily. assembly mentioned above, this was a relatively straightforward job involving a Acieta provides a broad range of robotics weighty component. "People had to pick out a technology for a number of manufacturing 4kg battery and put it into a stack to make up a industries, including automotive. Its robotic complete cell," he explained. "Nissan identified assembly systems are frequently used in the that there was a potential for repetitive strain production of components such as pumps, injury, so now the robot does some of this for motors and gearboxes. They come in three them. It's improving somebody’s job by taking configurations: six-axis articulated arms, four-axis away that kind of tedious task that could lead to ‘SCARA’ robots, and the ‘Delta’ configuration. an injury." The latter resembles nothing so much as a ceiling- mounted spider and uses motors in the base to The industry has long faced worker concerns move three linked arms. Manufacturers can add about the impact that automation will have on in sensing technologies such as vision systems to their jobs. Acieta addresses this concern head- guide a robot to pick up a component from a on with a dedicated 'Robotic Myths' section on conveyor, which reduces the need for precise its website. Contrary to the myth that robots location. A manufacturer can also specify force steal jobs, it asserts that automation is in fact sensing to help with part assembly operations like "necessary to bring part cost down so American insertion, giving the robot controller feedback products are competitive with the rest of the about how well parts are going together or how world." When a country's products are much force is being applied. competitive, then manufacturing companies will keep their operations in place and hire On the whole, Acieta suggests that “assembly more people, frequently in better job positions. line robots occupy a sweet spot between humans and dedicated or ‘hard’ automation.” Universal Robots expressed a similar view. "In general, robots don't just replace people," asserted Gray. "What tends to happen is the New technology, new jobs person works alongside the robot, the robot does the boring or repetitive tasks that the person They are also adaptable for emerging new shouldn’t be doing, and that frees up the person technologies, such as electrified powertrains. to handle inspections and use things that have Wisconsin-based company Rockwell more skill involved." In fact, Universal Robots has Automation provides a range of industrial found that the addition of automation frequently robots but has its eye on the rise of electric results in greater employment. "By improving vehicle (EV)-specific manufacturing productivity, you shift more products out the requirements. It is developing robots door, and typically you win more market share," specifically to help automate the manufacture of he added. "That then leads to ancillary jobs doing electric cars and their batteries. "The future of other things."

22 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

Maximising robotic paint shop potential will require human intelligence

While the use of robots in paint shops can bring huge savings, ensuring they are deployed effectively still requires human hands. By Jack Hunsley

he automotive industry is going through a car painted any color that he wants so long as it Tperiod of unprecedented change with is black,” approach simply would not fly today. connectivity, electric propulsion and autonomy While widely misunderstood, given that the rapidly becoming less like far-reaching Model T could be purchased in many colours concepts and more like potential short-term from blue to royal maroon, it was a standpoint realities. However, although the industry born of productivity—of all the available paints continues to boast about the pace of at the time, black dried the quickest. In today’s development of future mobility solutions, world, the need to juggle painting with thought is rarely given to the technologies that productivity remains and robots are being will make that future a reality. recruited to tackle the job. The paint shop has come a long way since the IoT and paint shop potential early days of automotive manufacturing. Indeed, Henry Ford’s “any customer can have a Just as automated vehicles have the potential to create a far safer and more efficient mobility system, robots can be used in paint shops to carry out tasks in ways that humans workers cannot. For example, in the stages of paint application, increasing connectivity, Internet of Technology can only Things (IoT) development and artificial “ intelligence (AI) maturity is allowing for achieve its potential in reduced paint usage, therein by saving money, combination with intelligent emissions and time. software “Overspray-free painting—which avoids fine droplets of paint landing outside the target area—takes into account the trend towards individualisation up to ‘batch size 1’ and this is why there will be a great impact of IoT and

Research by Automotive World 23 Special report: A fresh look at robots in vehicle manufacturing

Industry 4.0,” said Frank Herre, Senior To create the same effect previously, workers Manager Development Application/Process at were required to manually apply masking Dürr. “Technology can only achieve its tape to the vehicle before the second coat potential in combination with intelligent was applied, a process that could take up to software. We have to meet the highest 50 minutes. Not only does the EcoPaintJet standards in quality efficiency, overall remove the need for human workers to apply equipment effectiveness and lowest tape, but also eliminates the need for masking environmental impact.” tape at all courtesy of the fact that the solution does not produce any overspray. For Dürr, the paint shop clearly holds a huge “This is only possible using very precise potential in terms of savings. For instance, measuring technology, automatic path through its digital intelligence offerings— generation and a robot with maximum 3D DXQanalyze, DXQcontrol, DXQsupport and path reproducibility,” added Herre. DXQoperate—Dürr is able to provide a wholesale approach to ensure customers are Its work in the space has proven popular. In maximising their paint shop potential. For Vietnam, for example, it has worked with instance, DXQanalyze is used to create Vietnamese automaker VinFast to produce a transparency in the painting process by space-saving paint shop. In China, it announced allowing any faults to be quickly identified and in January 2019 that it was to aid Byton in acted upon. producing a paint shop at the start-up’s Nanjing facility, which Dürr claims reduces the physical Increasing robotic footprint of the paint shop by 20% while being capable of handling twice Byton’s envisioned complexity plant capacity. “High-quality painting at volume is impossible by humans, so we use precision This digital family can then be aligned with trained robots to ensure perfect coverage with painting-specific applications to refine painting minimal waste and exposure,” said Mark processes on the shop floor. For example, one Duchesne, Byton’s Vice President of area that is seeing increasing robot use is that of Manufacturing Operations of the painting two-tone painting. While the majority of solutions at the facility. “Our ovens used to vehicles offered to consumers today comprise cure the paint are accurately controlled to largely of a single colour, the use of robotics achieve a perfect bake and a great looking could allow for more complex painting finish without defects.” configurations and designs. Kenworth invests in paint With its EcoPaintJet solution unveiled in May 2019, Dürr became the first company to offer shop robots an automated solution in this space. Indeed, its Chief Executive, Jochen Weyrauch, In North America, the situation is very similar. described the development as “a quantum Commercial vehicle manufacturer Kenworth, leap in the journey toward the efficient two- for example, announced a US$140m investment tone painting of cars.” Dr Lars Friedrich, in April 2019 to build a new paint facility at its responsible for Application Technology at Chillicothe plant in Ohio. The money will be Dürr, added that “this high-tech process used to increase the truck maker’s painting enables the automotive industry to fulfil capacity at the site by 50% which, according to customers’ specific requirements faster while the company, will result in a 30% increase in ensuring top quality. There is great interest in efficiency and a 10% increase in overall the market, as we are offering real added production capacity. value with this new technology.” “The new paint facility in Chillicothe will enable For those eager to produce two-tone vehicles, us to increase production and build a paint the development is certainly revolutionary. facility that supports quality with growth for

24 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

increased total production when ready in 2021,” said Judy McTigue, Kenworth Assistant General Manager for Operations. “We will be more efficient by being able to meet market demand while painting the same number of trucks in two shifts that we currently process on three.” The technology will only be This increased efficiency will be achieved by “ the use of automated conveyance systems and valuable if it helps us to robotic paint, which Kenworth’s Chillicothe better meet customer and Plant Manager, Rod Spencer, described as state-of-the-art. Rather than chain market demands conveyance, skid conveyance will be used to increase uptime, lower maintenance costs and improve quality. “We’ll also be using gantry- mounted Fanuc robots with Bell sprayers, connectivity and power to this type of while the current shop uses floor-mounted analytics and help us on our journey of Fanuc robots with traditional spray guns. continuous improvement.” Improved applications will drive improved quality,” he added. Human expertise remains The use of robotic painting will also allow Kenworth to improve its environmental critical sustainability. These processes combined should cut its paint usage by more than 15% “Kenworth has many years of experience in and paint thinner usage by 40%, all while robotic paint,” added Spencer. “We have improving its product offerings. “Emissions will trained technicians and a good understanding also be reduced by a new thermal oxidizer of the up-front and sustaining requirements which is part of the project. Trucks will have for this type of manufacturing. With robotic higher gloss paint and we will be able to do paint, as with other manufacturing processes, more multi-colour cabs, both of which will help design and manufacturing need to work hand meet our customer and market requirements,” in hand on design changes. Programming, said McTigue. process time and quality of the end product all need to be taken into account when However, while change is clearly afoot for developing new designs.” Kenworth, this transition is seen internally as more of an evolution rather than a revolution. Overall, the future of automotive paint shops Given that automation and robotics have been looks set to become increasingly reliant on used for many years in paint shops, the robotics. A robot is inherently more efficient company recognises along with Dürr that the than a human in such a field and, indeed, each next step lies in incorporating these machines new iteration will unlock new potential for into IoT platforms. “Kenworth embraced cost, time and sustainability savings. However, technology on the plant floor many years ago maximising a robot's potential may still require by putting computers and workstations a human touch. While IoT development can throughout the factory floor,” said Shaun highlight potential issues or savings, acting Gorrell, Kenworth IT Manager. “This upon these recommendations can still benefit facilitated the development and utilisation of from human logic. “Human expertise and electronic work instructions, dashboards for experience will remain critical to interpreting, monitoring production performance and prioritising and acting on what we learn from throughput as well as the retention of data so analytics,” said McTigue. “The technology will that we could learn from what we were seeing only be valuable if it helps us to better meet each day. IoT will bring even more customer and market demands.”

Research by Automotive World 25 Special report: A fresh look at robots in vehicle manufacturing

Why in-plant logistics robots are quickly becoming essential

The increasing affordability and efficiency of in-plant logistics robots is becoming too significant to ignore. By Jack Hunsley

anufacturing by its very nature needs to Mbe a highly organised and efficient process. Any time or material lost between the start and end of a production cycle equates not Now we have the possibility only to wasted effort but also to wasted capital. “ Making sure that every aspect of any not only to save huge automotive plant runs smoothly is big business. amounts of money on As such, the industry finds itself at a investing in very inﬂexible fascinating point in its history. While talk of electrification and autonomy dominates products, but to use AGVs headlines and public attention, behind factory doors lies a potentially far more commercially to connect all lines and valuable revolution courtesy of in-plant other warehouses together logistics robotics.

Goodbye to the conveyor where it is needed. The result is a highly flexible manufacturing plant that can scale belt with demand and operate around the clock.

Rather than being reliant on a slow-moving “We have already begun a big initiative with conveyor belt and heavy load mobile robots to cobots and can introduce relatively cheap keep a factory ticking, a future production automation on existing lines,” explained Markus line could be made up of automated guided Fischer, the Head of Continental’s Regensburg vehicles (AGVs), robots and cobots. Through plant. “For more than 20 years we have had to the use of digitalisation and the Internet of stomach heavy loaded mobile robots which can Things (IoT), these three types of robots could only drive on their chains. Now we have the work in unison, with each having access to possibility not only to save huge sums of money data including current stock levels, on investing in very inflexible products, but also production times and plant layouts to know to use AGVs to connect all lines and other exactly what is needed, when it is needed and warehouses together.”

26 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

“This has made a big diﬀerence as we are now very ﬂexible thanks to these new technologies

As Fischer described, the process is very “To develop the EcoProFleet, we combined straightforward. A typical AGV, robot or cobot our process knowledge in mechanical and is able to look inside a database and identify plant engineering with intelligent material flow where manufacturing needs may arise and control,” said Stefano Bell, Product Manager. react in advance. For instance, a robot working “The energy storage concept with on a repetitive manufacturing task will be able supercapacitor technology enables 24/7 to notify other robots in a plant that it will soon uptime of the fleet without extra time for require parts or components from elsewhere in charging. In combination with our the facility to continue production. These other sophisticated control system, the AGVs can robots can then travel across the plant to find exploit their full potential as a flexible and the product, collect it and deliver it back to the efficient transport system.” original robot—all without human interaction. “This has made a big difference as we are now The root of such investment at Dürr comes very flexible thanks to these new technologies,” from a belief in increasing individualisation in added Fischer. manufacturing. Whereas in the past an overwhelming majority of products were Continental is not the only player to have largely standardised, changing consumer realised the value of automated logistics. demand and increasing manufacturing According to research conducted by the competency has created a market for more International Federation of Robotics, the use of unique product offerings. In order to match logistics robots has exploded in the space of this demand, change is needed. half a decade. 2017 for instance, saw 69,000 units installed in plants across the world, Indeed, at Dürr the belief is that paint shops marking a 162% increase compared to 2016. will increasingly turn away from the production The federation estimates that between 2019 line and instead opt for modularity aided by and 2021, 485,000 units will be sold. robotics. “In the paint shop of the future, car bodies will be moved independently and in a Individualisation parallel formation between modular designed workstations, finishing booths, and intermediate storage,” said Bell. “Industrial IoT As such, Continental’s industry competitors are solutions will allow for this increase in also keen to get in on the act. Dürr, for performance and easy maintenance.” example, has designed an AGV specifically for use within automotive paint shops. The Individualisation will not solely be left to company claims that its EcoProFleet solution painting, however. For instance, Bosch has also will play a decisive part in developing smart developed an automated shuttle solution for in- and efficient paint shop processes in the paint plant intralogistics operations which is designed shop of the future. to handle increasing individualisation. Here, its

Research by Automotive World 27 Special report: A fresh look at robots in vehicle manufacturing

In the future, as new and smarter equipment is installed there will “be a greater focus on software than hardware. That data is needed to ensure ﬂexibility and to continue improving

ActiveShuttle concept is designed to handle Fortunately, there are ways in which the these changing product demands by providing transition can be simplified. For instance, an automated transport system that can operate Continental has adopted a highly standardised quickly and flexibly. approach to the problem where both the robots themselves and the software that drives them are It achieves this by transporting dollies, which tightly defined. As such, it matters little whether are also loaded and unloaded autonomously, Continental is introducing robots in Europe, Asia with small load carriers through factories. The or North America as the company knows exactly company claims that its laser scanner what these robots are capable of, where they can technology and ActiveShuttle Management be best applied and how to apply them. System allows the ActiveShuttle to be integrated seamlessly with existing “All this data is kept in the cloud so we can intralogistics operations and, therefore, it can carry out big data analysis and target AI work alongside existing infrastructure and approaches,” said Fischer. “In the future, as transport vehicles flawlessly. new and smarter equipment is installed there will be a greater focus on software than hardware. That data is needed to ensure Ease of transitioning older flexibility and to continue improving.” plants Going forward, therefore, the responsibility of in-plant logistics is likely to fall even further This seamless integration potential is of into the hands of robots and computer code as, particular importance. While such rapid change put simply, the benefits are too good to ignore. of pace is promising from a productivity Not only can automating these processes create standpoint, for older facilities there is potential a highly efficient and automated manufacturing that the arrival of in-plant logistics robots could procedure that can significantly save time and disrupt well defined and established means of money, but they can also be implemented at production. For any new facility, the choice to very affordable prices—Fischer, for example, opt for a robot such as an AGV is obvious, but estimates that a typical cobot can cost as little for pre-existing plants integrating new robots as €20,000 (US$22,431). into existing lines could potentially prove troublesome. “They are not sustaining each and every one of our plants at the moment but increasingly, the “It is easier if you build new greenfield plant as internal material flow will be substituted by you can implement AGVs much easier than in an AGVs,” said Fischer. “At the moment in existing plant that is already full of machines,” Regensburg we have about 15 of these robots said Fischer. “Although achieving these levels of running 24/7 and in the next few years, automation in older plants is much more internal material flow conducted by humans difficult, it cannot be avoided. It is vital to carry will be a thing of the past. With mobile robots, out this transition in order to remain there are very cheap possibilities to optimise competitive, especially in high-cost countries.” the internal supply chain.”

28 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

Digitally linking robots can enable safer, more efficient manufacturing

Increased robot adoption will allow players to create safe, flexible and more efficient production lines, says Continental. By Jack Hunsley

utomation is a concept that is rapidly taking Athe automotive industry by storm. Whether it is automating bus routes, vehicle maintenance cycles or long-haul trucking, automation has the potential to create a more In Industry 4.0, the cobot efficient, sustainable and safer world. However, “acts as my arm. The while all of these concepts are very public facing, behind the scenes automation is also automated guided vehicles hard at work. (AGV) are my feet. Those Automotive manufacturing can often be a robot’s camera sensors are complex process. Anyone that has visited a manufacturing plant will have some concept of my eyes the size, scale and organisation that is required to remain competitive in the market. Here robotics and automation could play a significant role. Continental’s electronics plants. As he detailed, the arrival of Industry 4.0 is breathing new life Industry 4.0 into automotive manufacturing robotics. “Each and every machine now has an IP “Automation and robot use is not a new address and the robots can interact with each concept because we have been automating machine, database and required software,” he manufacturing processes for 40 years now. explained. “This is the new thing with What is new is the arrival of Industry 4.0,” said Industry 4.0 as it is allowing us to combine Markus Fischer, Head of Industrial Engineering those forces.” at Continental’s Regensburg plant, the company’s largest automotive manufacturing The concept is rather simple. While robotics facility. Fischer is not just responsible for the has long been used to automate individual introduction of Industry 4.0 for Regensburg, procedures, the arrival of digitalisation is but also oversees this digitalisation for all of allowing Continental, and the wider industry,

Research by Automotive World 29 Special report: A fresh look at robots in vehicle manufacturing

In the future, because of the speed at which customer needs “are changing, we need completely new line concepts to cater for that

to better integrate these processes. Bosch, for future, because of the speed at which customer instance, has developed a range of flexible needs are changing, we need completely new Industry 4.0 compatible cobots which are line concepts to cater for that. Robots will play capable of working uncaged alongside humans a very important role,” said Fischer. in tasks such as loading and unloading of machines or product inspection. Indeed, its As Fischer detailed, if such integration is done APAS robots are designed to be slim enough to successfully, the industry could see robots and integrate with existing production lines and, cobots replace the traditional role of a depending on the complexity of their use case, conveyor belt. Rather than relying on a can be fully automated. The overall result is a continuing slow-moving belt to move parts and more streamlined manufacturing process. components from section to section, Industry 4.0 could unlock the potential for cobots and “Take a relatively cheap cobot that doesn’t robots to take products directly where they need a cage,” said Fischer. “In Industry 4.0, the need to go in the factory, creating a more cobot acts as my arm. The automated guided efficient and flexible process. vehicles (AGV) are my feet. Those robot’s camera sensors are my eyes. This is the way we “The production line will look completely are thinking about automation and robotics at different in just five years,” Fischer told Continental.” Automotive World . “The delivery of the components and materials needed to produce a New line concepts product will be fully automated. It will be highly flexible because robots can be updated quickly and replaced easily when better and It is with this increasing integration that robots cheaper cobots become available.” could define future automotive manufacturing cycles. While today’s manufacturing plants are all highly linked and work in relative unison, Human and robot interaction the arrival of integrated robotics could allow the industry to completely rethink the typical is the norm production line. Digitally linking a series of robots and cobots can allow companies to A common talking point when automation redesign their factory layouts and achieve comes to the fore is how future robots will significant cost and time savings that will allow interact with humans. Diminishing job manufacturing to keep pace with future opportunities in automotive plants in the UK mobility development. and North America, for example, only reflect the tension that the prospect of cutting manual “When you look today at a normal production labour can incite and how the perceived line you have a conveyor belt with some looming threat of automation can manufacturing processes integrated. In the understandably unnerve some workers.

30 Research by Automotive World Special report: A fresh look at robots in vehicle manufacturing

However, in the case of robotics, the aim is not to replace human workers, but rather to lighten their load.

In Regensburg, for example, Continental has already implemented around 60 cobots to aid Non-ergonomic or heavy its human workforce. Largely these cobots are “ used in parts of the line that are unergonomic lifting tasks can be diﬃcult, for human workers, or where heavy lifting or especially for especially our repetitive tasks are required. In these often non-value adding processes, the increasingly older workers. The people obvious choice is robotics. “It is much easier now that we have implemented these cobots,” on the shop ﬂoor have said Fischer. “Non-ergonomic or heavy lifting nothing against our cobots tasks can be difficult, especially for our older workers. The people on the shop floor have nothing against our cobots.”

In addition to carrying out non-value adding important element in keeping pace with tasks, robotics can also help minimise worker future mobility development. While risk. At one of its casting plants, General Motors manufacturing an EV is largely the same as uses drone technology to inspect sand delivery manufacturing an internal combustion engine pipes. For a human worker, such a procedure (ICE) vehicle, bar the obvious differing is time-consuming and dangerous given the powertrain requirements, the speed at which location of the pipes at considerable height. A consumer demands are changing is beginning drone, flown inside a cage, is used instead, to place new strains on traditional enabling remote visual inspection for cracks or manufacturing. Here, robots can help. any potential areas of concern. Should anything be identified, human expertise and dexterity “Vehicle electrification definitely influences our takes over, but the use of the inspection drone factories but on the other hand, electronics is reduces human operators’ exposure to electronics, and for the factory it is largely the dangerous situations. same. What is really different is that future product cycles will be much faster,” said It comes as little surprise, therefore, that many Fischer. “With those cycles, you have to react factory workers have become fond of their quickly in manufacturing with new products robotic counterparts. Indeed, according to and improved quality.” Fischer, at Regensburg workers have given their robots names—Hans and Jochen are two Overall, despite the history of robotics in representatives of Continental’s robotic automotive manufacturing, there is still huge workforce, for example. “We’ve been potential for players to expand their automating for 40 years. Our people are not knowledge and use of robots and cobots. against automation because this type of According to the International Federation of technology is not new for them,” added Robotics, for example, there are just 84 Fischer. robots per 10,000 workers in the US on average. In Europe and Asia, this figure is at New demands need new 99 and 63 per 10,000 respectively. While the complexity of manufacturing means that approaches automotive plants are unlikely to ever operate completely unassisted, there is Beyond the obvious benefits of improved takt clearly room for growth. Those that embrace time and cost savings, the increasing the robot are likely to reap the benefits in the introduction of robotics is seen as an coming years.

Research by Automotive World 31