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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 Copyright statement Published in July 2019 by : © 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
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