Cobots (Collaborative Robots) in Advanced Manufacturing

Cobots (Collaborative Robots) in Advanced Manufacturing

Cobots, or collaborative robots, are advanced automation systems designed to work safely alongside humans in shared manufacturing environments, boosting efficiency and reducing workplace risks. PBC Linear, a leader in the production of bearings, actuators, guides and shafts, is leveraging these cobots to build on its strong foundation in lean manufacturing. By integrating cutting-edge automation technologies, PBC Linear is transforming its production processes to handle repetitive, labor-intensive, and high-risk tasks, such as precision assembly or material handling, that once posed injury risks to workers. This shift enables the workforce to focus on elevated skillsets, including advanced inspection and quality assurance of bearings and shafts. Enhanced by emerging technologies like augmented reality (AR) for training (e.g., Magic Leap 2), PBC Linear is creating a leaner, smarter, and safer factory with significantly greater output, aligning with modern automation trends and workforce development goals.

This article and the video below are part of a longer series that details how PBC Linear is incorporating such technological enhancements into its production systems. The following content offers an introduction to collaborative robots, the insights gained during their implementation, and the resulting benefits to our workforce, business, and most importantly our customers.


Image for Manual vs Automated Methods

Cobots are collaborative robots. Both the name and the description reflect their ability to work side-by-side with the human workforce to safely achieve greater output efficiency and quality. The cobot fulfills its role by utilizing these fundamental advantages:

  • Built-in sensors that interact with servo motors, making them extremely safe and user-friendly. For example, if there is a force limit that is exceeded by bumping into an operator or other object, the cobot will sense this, stop, and then require a reset to restart the operation.
  • Higher efficiency in repetitive labor such as pick and place, resulting in higher product output.
  • Ease of performance of previously hazardous tasks, where risk of injury exists from heavy lifting or running machines.

These cobot strengths also allow workers to be reestablished into higher skilled roles. Now, the technician that had previously mastered this work will instead be monitoring the cobot, or multiple cobots, while simultaneously checking for quality, providing processing feedback, and making fine-tuned adjustments.

Tim, the Director of Manufacturing, offers his views on Manufacturing

Tim L., Director of Manufacturing

A cobot is an excellent assistant that can aid the team by taking over the basic functions of loading and unloading the machine. However, it is limited in its ability to discern whether a part is good or bad, making it just an extension of the machine. This allows us to train the operator to focus more on the quality of the parts.

Cobot working collaboratively with Workforce

Cobots and the labor force

As we continue to move further into this decade, it has become evident that the entire manufacturing sector is dealing with a shortage of skilled labor. Some factors for this shortfall include lack of promotion within high schools and higher education, and the simultaneous retiring of older, skilled workers. The result of these outside forces has produced a gap of qualified personnel that businesses are struggling to fill. As one solution, the cobot brings the potential to satisfy some of those existing labor needs.

In addition, when PBC Linear brings on a new hire, there is a steep learning curve that involves training on both the running of the equipment and the inspection of parts. It’s a lot to learn at once, but by applying the assistance of the cobot to take over some of the basic functions, we can now focus operator training on quality and inspection.

Meet the Cobots

The first impression of our cobots can be described as sleek, shiny and clean. They have six joints for smooth motion, allowing them to twist and turn to fit many different task configurations. Unlike some other comparable machines, our cobots have a set of control buttons on the tool end affector that allows operators to teach a point by simply pressing a button and then moving the cobot to the desired position. All of this can be done without a bulky pendant, allowing for more control during the programming stage.

Cobots, or collaborative robots, can be programmed by engineers to perform sophisticated functions, such as executing open and close door operations or running custom macros to enhance manufacturing efficiency. For instance, a cobot can be programmed to place every tenth part into an inspection station. Once the part is in the station, engineers can implement a pass or fail logic, where a failed part triggers the cobot to pause automatically, awaiting operator intervention for adjustments. This advanced programming, integrated with technologies like augmented reality (AR) for real-time guidance (e.g., Magic Leap 2), enables PBC Linear to optimize production processes, ensuring precision and safety in manufacturing tasks.

Build your complete cobot automation package
from Applied Cobotics!

Cobots

Cobots

cobots

The value of cobots

For years, PBC Linear had considered installing robots. Unfortunately, pricing, plus safety factors such as barrier fencing and door interlocks, made it far more costly that any labor-saving benefits from industrial robots. More recently, the company owners have had the opportunity to witness a few of these cobots in action. After careful analysis, they realized the automation potential and affordability of these machines. In fact, the price-point of a cobot generally results in a very short return on investment.

Tim L., Director of Manufacturing, offers advice on the economics of cobots

Tim L., Director of Manufacturing

Cobots will be a necessity to stay in business within this economy. Imagination is the only limit. So far, we have not found a manual operation that cannot be programmed and performed by our cobots.

Beau W., Mechanical Engineer, Cobot Project Manager 

The bottom line is increased production. Collaborative robots contribute to a significant increase in the number of cycles we can run, as well as the time of day when we can run those cycles.

Click here to Calculate your ROI