5 Ways Cobots Are Boosting the Efficiency of Automotive Manufacturing Processes

Designed to work side-by-side with humans, collaborative robots (cobots) are quickly becoming an integral part of automotive manufacturing. As the need for greater precision, adaptability, and efficiency grows, cobots stand as a dynamic solution to these challenges.

But how exactly are cobots redefining the role of human labor in automotive manufacturing? What unique capabilities set them apart from other technologies?

In this article, we’ll explore five ways cobots are supercharging automotive manufacturing efficiency, along with examples from industry leaders.

1. Enhancing Precision and Speed in Manufacturing

The keys to any manufacturing process are precision and speed, particularly in automotive manufacturing. Cobots have become essential for meeting consumer demands. They’re revolutionizing production by improving accuracy and speeding up manufacturing cycles.

Cobots work alongside humans, handling repetitive tasks with superior precision. This is crucial in automotive manufacturing, where a small misalignment can be costly or even unsafe. By preventing such errors, cobots virtually guarantee high-quality finished products.

Equipped with advanced sensors and capable of continuous operation without fatigue, cobots keep production going at a steady pace, minimizing downtime.

Take BMW as an example. By implementing cobots in assembly lines, the manufacturer improved both precision and speed. The result? A significant increase in production rates.

Cobots have also changed the way plants handle tasks like parts placement. These tasks are susceptible to human error and time-consuming adjustments. Cobots can place each part with extreme accuracy, cutting down defective products and eliminating the need for readjustments. This reduction in manual work not only improves product quality but also speeds up the production process.

2. Reducing Errors in the Production Line

Thanks to their remarkable precision and consistency, cobots are uniquely suited to minimize production line errors. They perform tasks with a level of consistency humans can’t replicate, executing each action with equal precision.

Cobots can easily handle complex, risky or monotonous tasks, minimizing human-induced errors. Their ability to operate consistently in harsh conditions and handle hazardous materials promotes a safer workspace and less error-prone processes.

For example, Ford uses cobots for a range of tasks, like painting and quality inspections:

In painting processes, cobots can precisely maintain distances and angles and repeat motions consistently. This ensures each vehicle is painted uniformly, vastly decreasing the need for rework.
In quality inspections, Ford’s cobots have significantly boosted defect detection. Their advanced sensors and cameras can scrutinize parts and assemblies more accurately and quickly than humans, spotting minor defects that the human eye could easily miss.

Since using cobots, Ford has seen a drop in product recalls, demonstrating cobots’ value in error reduction.

3. Handling Complex Tasks with Ease

A significant feature of cobots is their easy programmability. Even for the most complicated tasks, cobots can be set up and adjusted for different roles in the assembly line. This adaptability reduces downtime, as cobots can move swiftly between tasks without extensive retooling or reprogramming.

They often come with adaptable physical configurations, allowing for modifications based on task requirements. Whether it’s a change in the end-effector tool or work envelope, cobots can be adjusted for specific tasks.

Mercedes-Benz demonstrates how cobots excel at complex tasks. The company incorporated cobots into assembly lines for intricate tasks like wiring installations.

These tasks, requiring precision and adaptability due to varied wiring configurations across car models, were traditionally tough and time-consuming for humans. But with cobots’ precision, Mercedes-Benz has seen significant improvements in error reduction. Their flexibility allows for quick adjustments to different wiring configurations, reducing task-switching downtime.

4. Streamlining Human-Cobot Collaboration for Efficiency

Unlike traditional robots needing separate workspaces for safety reasons, cobots are designed to safely work alongside humans. The connected worker blends human ingenuity with the precision and endurance of robots for better task execution.

Cobots and humans can work in sync, sharing and responding to real-time data. They can perceive their surroundings and adjust their actions, which enables productive interaction with human colleagues. This real-time data exchange optimizes the manufacturing process, as cobots and human workers adjust their behavior in response to each other.

A key feature of this collaboration is task distribution. Cobots are often tasked with strenuous or repetitive jobs, freeing humans to focus on tasks requiring complex decision-making and creativity. This lessens injury risk and worker fatigue and allows workers to focus on high-value tasks.

For instance, Audi integrated cobots into assembly lines to enhance safety, productivity and job satisfaction. It uses cobots to handle monotonous and strenuous tasks like applying adhesives or installing heavy components, freeing workers to focus on tasks requiring critical thinking and quality control.

Lastly, cobots’ sensors and safety features allow them to work closely with humans without posing risks, reducing workplace accidents.

5. Facilitating Rapid Changeover and Flexibility

Cobots’ flexible design and wide range of compatible end-effectors enable them to handle diverse tasks, providing greater versatility on the production floor. They offer automotive manufacturers an agile tool that reduces changeover time and can adapt and evolve in sync with changes in production.

Tesla has leveraged the programmability and versatility of cobots to stay responsive to changing market needs. On Tesla’s production lines, cobots are frequently reprogrammed to perform different tasks based on production requirements.

A cobot initially set for installing battery packs can be swiftly reprogrammed for final quality checks or any other necessary task. This rapid reprogramming allows Tesla to adjust its production lines quickly, minimizing downtime and maintaining productivity.

Sensor Technology Interface: The Backbone of Cobot Efficiency

When we dive deeper into the world of cobots, it’s clear that their efficacy in automotive manufacturing is largely attributed to their advanced sensor technology interface:

Force-torque sensors. Torque transducers allow cobots to detect forces and torques applied to them, allowing them to respond to external pressures instantaneously. If a human accidentally pushes against a cobot, the sensor ensures the robot stops or adjusts its movement, preventing potential accidents.
Vision sensors and cameras. Cobots often integrate high-resolution cameras and vision sensors to “see” their surroundings. This is vital in tasks like quality inspections or parts placement, where precision is paramount. Advanced image processing algorithms enable these robots to detect defects, ensure correct component placement, and even recognize and adjust to varying parts and models.
Tactile sensors. Piezoelectric, piezoresistive, capacitive and elastoresistivity sensor types grant cobots the ability to “feel” the objects they interact with. This technology is vital for tasks like installing delicate parts or handling fragile components. By gauging the texture, temperature and pressure, cobots can adjust their grip or force applied, ensuring they neither drop nor damage the components.
Proximity sensors. Capacitive and various types of detection sensors help cobots maintain a safe distance from humans and other objects. By continuously scanning their surroundings, cobots can pause or change their path if they detect an unforeseen obstacle, thus ensuring safety without compromising efficiency.

Feedback loops and control algorithms play a pivotal role in enhancing a cobot’s adaptability. By continuously receiving data from its sensors, a cobot can adjust its movements, speed or force in real-time. While far from perfect, their increasing adaptability allows manufacturers to explore using cobots for more and more use cases.

Cobots and Humans Working Hand-in-Hand

Cobots are undeniably changing the game in automotive manufacturing. However, ongoing training and education are necessary to seamlessly integrate cobots into manufacturing processes.

While cobots are safety-oriented, we must prioritize worker safety when working with them. This means implementing robust safety protocols, conducting regular risk assessments and ensuring quality communication for safe human-cobot interactions.

How can we tap into the capabilities of cobots for even greater efficiency? And how can we cultivate a work environment that blends cobots and humans seamlessly while prioritizing safety and satisfaction? The answers will shape the automotive industry's trajectory in the coming years.

Eric Whitley is a longtime leader in the manufacturing space. Currently the director of Smart Manufacturing at L2L, he previously led the Total Productive Maintenance effort at Autoliv ASP and served as an adjunct faculty member in the Management Certification programs at The Ohio State University.