Repeatability and Accuracy Myth
Jay M. Wong • June 18, 2020
Robotics Myth 1: Repeatability and Accuracy
The global robotics market (estimated value at $39.72B in 2019) is expected to continue to blossom (hitting $248.5B by 2025). Various factors are driving this: the introduction of more sophisticated hardware at lower costs, the resurgence of “deep” learning and artificial intelligence technologies, and the growing challenges with the labor demanding more automation for throughput, safety, mass customization, and logistics.
Up to this point in the growing robotics market, we’ve seen much speculation, bombastic claims, and unfulfilled promises. Over these past years, these claims have led to a number of devastating robotics company closures either due to unsatisfactory product-market fit or romanticize underperforming technology, leaving many founders and investors learning what is myth and what is reality post mortem.
The purpose of this “Robotics Myths” blog series is to highlight some of these robotics myths, so that new founders and investors do not have to make the same mistakes, being wiser when informed by history. In addition, this blog aims to present the limitations of robotics today, shedding light to warehouse owners and individuals looking to automate, so they can make informed decisions when sourcing automation technology. Lastly, this blog series serves as a means to promote conversation, wherein us roboticists can freely discuss and clarify myths, in hopes of making the fundraising process, customer conversations, and customer expectations easier.
On Repeatability and Accuracy
Today, we are kick starting this blog series talking about repeatability. We’ve all had that one conversation with a sales representative from your favorite robot vendor claiming their robot is far more superior than their competitors due to 1) the robot’s reach and extra degree of freedom (DOF), 2) the robot’s speed and payload, or 3) the robot’s impeccable repeatability and accuracy.
To the first claim, of course, having additional reach and DOFs directly impacts the robot’s
kinematics and workspace. As a result, these factors influence the task’s feasibility (whether the robot can physically perform the task). To the second claim, the payload specifications are dependent on your task. The target robot should have sufficient payload to account for the tooling and picking parts. Clearly, the justification for robot speed is simple: faster robot speed means faster cycle times which in turn increases return on investment (ROI). However, the third claim that Robot X is better than Robot Y simply due to its repeatability is, in general, a bogus claim.
A good blog post discussing repeatability and accuracy by Robotiq.
We define accuracy as the difference between the requested (desired) task and the obtained (result) task, whereas repeatability is a measure of the variance of all obtained tasks. To better understand repeatability and accuracy, we refer you to
this blog post. For the rest of this post, we will use repeatability and accuracy fairly interchangeably, sometimes simply referring to them as the robot tolerance, since off-the-shelf robots tend to have repeatability and accuracy measures within the same order of magnitude and the argument presented in this blog is applicable to both.
What is YOUR Repeatability?
First, let’s perform a quick exercise to better visualize and understand these concepts. Grab a piece of paper and a marker and draw an “X” in the center of the paper. Now position your hand with the marker about a foot away from the “X”, close your eyes, and try to point at the “X”. Repeat this 10 or 25 times. You may open and close your eyes between each attempt. Notice how far off the dots (results) are compared to the “X” (target). This measure is your accuracy. The spread or the variance of the dots is your repeatability.
If your results are similar to mine, we notice that our kinematics as humans are not very good. The accuracy (difference) and repeatability (variance) of the dots against the true target (the “X”) and to each other are large. This exercise is comparable to how we test and control robots today. Robots are given a target within their workspace and rely on their precise kinematics to achieve that target. Even in the case of introducing vision systems and sophisticated (“deep”) perception algorithms, in most conditions, the system localizes (determines precisely) where the target is first. Then, the system computes a goal (or a path) for the robot to achieve this target. In robotics, we call this the
sense-plan-act paradigm (or sometimes called
OODA loop), wherein robots perform each of these steps in series and essentially “closes their eyes” during their planning and acting phases.
An exercise: draw an “X” on a piece of paper and try to point at it with your eyes closed. What is YOUR repeatability and accuracy like?
Compared to humans however, robots are multiple orders of magnitude more accurate and repeatable kinematically. Pull up the data sheet for your favorite robot and you’ll notice that their repeatability measures are quite often on the order of 0.1mm or better (a measure describing the difference between the dots to each other and to the “X”). I would argue that humans are, at best, cm-level precision kinematic systems. But if humans are so “erroneous” how do we ever accomplish precise manual tasks? We will cover this question later in this blog. But first, let’s revisit repeatability for robots.
Repeatability is a Function of Your Task
Remember that the premise here is the claim that Robot X is better than Robot Y simply due to its repeatability (and/or accuracy) is, in general, a bogus claim. Of course, you may be thinking, there exists a subset of tasks that indeed, do require high levels of accuracy and repeatability (e.g. precise assembly, insertions, welding, and Q&A). These tasks can be categorized generally under
low mix and extremely high volume throughput processes. For these tasks, the robot is set up, programmed, calibrated for a single task and is expected to execute without failure for millions of cycles with little to no process change.
The tight coordination of multiple robots tasked to perform car assembly in a factory requires fine precision and high repeatability (Image Credit)
Packing Amazon delivery boxes is one of many tasks humans currently do that do not require extremely high repeatability (Image from CBC)
Another packing task requires manual placement of objects into particular partitions. This task has a tolerable margin of error. (Image Credit)
Now, the majority of tasks, like material handling, pick and pack, and fulfillment, do not require the micron-level (or even mils-level) precision that these high fidelity processes require. A good example is to think about your latest Amazon order: the contents within the box are not necessarily packed into the box with micron-level precision, nor do you care. This particular task does not require that your Amazon item be placed precisely 5.289cm away from the top right corner of the box. Instead, the packer places the objects loosely into the box at some relative positions such that the contents fit into the container (i.e. the box). Another example of this is when humans manually place objects into particular partitions, blister packs, or sections. This also does not require such fine levels of detail. In fact, the bulk of “automatable tasks” fall under this category: loose place parametrization with some variability and some acceptable margin of error.
The necessary repeatability is then a function of the task itself. How much repeatability is required is outlined by the acceptable margin of error that constitutes task completion and success. For example, a task like assembly might actually require micron-level precision with parts that have to be inserted into one another with sufficiently tight tolerances. Whereas, a task like packing an Amazon box can be done “fairly erroneously” under the conditions that the objects are not damaged, they end up in the box, and they do not constrain the box from being closed properly.
How Much Repeatability Do We Need?
In this case, success need not be defined by having zero error or having perfect repeatability. Rather, success is defined as whether the agent (a human or robot) performed an action that resulted within the task specifications and tolerances. In other words, success describes whether the tolerance of the task is met.
In robotics, we call this the
region of attraction or basin of convergence (or “funnels”). We can think of this as how much error can the task (and system) tolerate before success is no longer guaranteed. In the case of the manual packing of objects into their individual partitions (in the above image), the idealized placement is to place the object perfectly vertical into the compartment. However, the task itself can still be successful if the human places the objects 5 degrees from vertical. Similarly 10 or 25 degrees away from the idealized conditions should still result in the object falling into the correct compartment due to gravity and the object’s contact with the partition walls. We would describe this task as having a fairly large basin of convergence (of about, say, 25 degrees).
The basin of convergence of a task can be described by how far away from the idealized conditions can we go before success is no longer guaranteed. Visually, this can be illustrated by a funnel over the ideal conditions, in which states that are “sufficiently close” to ideal will still converged to success. Simply put, imagine a marble placed in the interior of the funnel. It will always converge towards the center.
Since repeatability is a function of the tasks itself, a robot must have sufficient repeatability to reliably fall into the basin of convergence of the task. So if the task has an acceptable margin of error of +/- 2.5cm and 25 degrees (like the example packing task above), then minimally, the robot should have a repeatability of +/- 1cm or so, such that if the robot is to target the ideal conditions, any perturbations or errors away from ideal will still converge to success.
Our Robots Are Already Precise Enough
Given our task’s margin of error, let’s investigate some robot arms currently in the market and their reported repeatability (according to their public data sheets). Our image here is by no means a complete listing, but notice that every single robot has repeatability measures less than a tenth of a millimeter!
The repeatability of various robot arms currently in the market are ALL sufficient for automating manipulation tasks.
The reported repeatability measures are well within the basin of convergence of the task. Compared to the tolerance of the task (+/- 2.5cm), the repeatability of each of these systems (at worst 0.1mm) is negligible. To put things into perspective, the magnitude difference is identical to driving for 15 minutes (i.e. a distance of 15 miles) and comparing that to the radius of the earth (~4000 miles). The only reason you see any significance between the task and robot tolerances (to the right) is that this plot is artificially inserting white space for visualization purposes.
Robotics and automation is an integrated science. It relies on the tight integration of hardware, control, planning, and vision systems. The takeaway here is that perception (vision) and control errors will far outweigh the precision of the robot (assuming <0.1mm), thus making this robot differentiation metric pointless.
Of course, there are other specifications to account for when selecting your robot for your task (i.e. reachability, kinematics, payload, speed, safety, ease of use, etc), but in terms of repeatability alone, any of these robots are sufficient. In fact, it does not matter which of these robots you select. They are all sufficiently precise for our example task, being orders of magnitudes less than the requirements described by the basin of convergence. Unless your task requires a peg-in-hole insertion of parts that have tolerances of several mils, the repeatability of these robots have almost no contribution. What is more important is how you control your robot, to achieve task success. In other words, the main contributor is how you control (and drive) the robot towards the basin of convergence specified by the properties of the task. The magnitude of your control paradigm and vision errors will far outweigh the magnitude of the robot errors (e.g. repeatability and accuracy).
Human Cm-Level Repeatability Still Prevails
In this blog, we had argued that humans are at best cm-level In this blog, we had argued that humans are at best cm-level precision systems. But if humans are so “erroneous” then how do we ever accomplish any manual tasks that require tight tolerances like assembly? And why do we still see humans doing so many precise manual tasks?
Revisiting our “target the X” example previously, if you attempt to do this task with your eyes continuously open, you’ll notice that you’re always going to be hitting the center of the “X”!
An example of how one attractor may stably converge into the region of attraction of another (Image source)
Humans may have worse kinematic repeatability, but we have a larger basin of convergence when we interact with the environment and the task via sensing and control. The reason is that when we perform tasks, we do not rely on kinematics alone, but instead leverage several sensory modalities to collectively provide feedback during execution of the task. We continuously leverage our vision during execution (see visual servoing), exploit contact and physics with the environment, and reason in both our audio and haptic channels. By collectively exploiting all our sensory channels, we in essence “grow” our basin of convergence. You can visually think of this as tiling a number of these regions of attractions (“funnels”) together to aggregate a much larger capture radius, where each of these funnels converges the state into the attraction of another funnel continuously towards the goal or success.
Robots are not quite there yet, in terms of leveraging a number of their sensory feedback harmoniously to achieve precise sensorimotor control. In many cases even, robots avoid the rich feedback (and contact dynamics) from the environment. A good example is that today, humans exploit contact whereas robots avoid contact.
Until robots can leverage multimodal sensory input (akin to humans), the repeatability of the robot should be considered for success.The measure of that requirement is proportional to the task at hand and the sophistication of control and feedback inherent in the system. Simply put, lower tolerance tasks require lower tolerance robots and higher tolerance tasks require higher tolerance robots. In regards to control, no feedback and no sensing requires more repeatability and accuracy, while moderate amounts of sensing requires less repeatability and accuracy. Measures of accuracy and repeatability are things to consider, but what is even more important is
what you’re trying to automate,
how you use the system, and the magnitude of these tolerances in relation with one another.
Conclusion: Spec to Your Needs
If you’re a supply chain expert looking to purchase new robot hardware and maximize your investment, we encourage you to first evaluate your task and its acceptable margin of error to determine what repeatability specifications your system requires. It’s important to ask yourself how much repeatability does your task actually need? Chances are you'll find your task does not require micron-level precision or even mm-precision. Chances are you do not need to spend more on repeatability, but rather your largest ROI justifier is speed and installation ease.
Of course, as our algorithms and control paradigms continue to improve (as we design more sophisticated methods to exploit feedback), the larger the basin of convergence and acceptable margins of error your task (and robot) may tolerate. And as these innovations and technologies emerge, we’ll likely see less of a need and demand for extremely precise robot systems. Perhaps, that is what the late Rethink Robotics had envisioned all along (unfortunately witnessing the difficulty
merging complex control and elegant actuation)…But in due time, one day when our control paradigms reign supreme and hardware becomes a commodity, we’ll be able to offset these major hardware inaccuracies through software alone, paving ways to more and more capable automation. But until then, coupling
moderately good control algorithms and
sufficiently accurate robots is more than enough to get the job done.
About the Author
Jay M. Wong is an entrepreneur, roboticist, and co-founder of Southie Autonomy. He leads the engineering effort on Southie’s no-code flexible automation system which couples augmented reality and artificial intelligence to enable a spatial ease of use robot interface to humans.
Wong worked as a robotics scientist at
Draper and held visiting scientist roles at MIT and Harvard University, where he served as an autonomy expert on a large research project to mature autonomous mobile manipulation technology. He led Draper’s cloud robotics research initiative and development on the
award-winning robotics system. Prior, he was at NASA and UMass Amherst, his alma mater, where he was named a fellow and two-time
OAA awardee.
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Flexible automation solutions offer a range of benefits that directly address the challenges posed by high-precision automation: Adapting to Marketing Trends: With flexible automation, manufacturers can swiftly adjust production processes to align with emerging market trends. Whether it's introducing new product variants or modifying existing offerings, flexible systems enable agile responses to evolving consumer demands. Personalized Packaging: Personalization is now key to capturing consumer attention and flexible automation allows for the customization of packaging designs and product configurations. By leveraging adaptable technologies, brands can cater to individual preferences without sacrificing efficiency or scalability. Seasonal Packaging: Flexible automation facilitates the seamless transition between different packaging requirements. Therefore, manufacturers can easily accommodate seasonal variations in product packaging. Efficiency and Cost-Effectiveness: High-precision automation requires significant reconfiguration or investment to accommodate changes. On the other hand, flexible automation solutions offer inherent scalability and versatility. This allows manufacturers to optimize production processes without incurring excessive expenses. Enhanced Agility: Flexible automation empowers brands to respond swiftly to market fluctuations and competitive pressures. By embracing adaptable technologies, manufacturers can capitalize on opportunities and mitigate risks more effectively, maintaining a competitive edge in a rapidly evolving landscape. Trending Flexible Automation Solutions In response to the limitations of high-precision automation, manufacturers are increasingly turning to a variety of flexible automation solutions. These technologies offer the versatility and adaptability needed to address the challenges posed by rigid automation systems: Robot Arm Solutions: Robot arms are versatile automation tools that can perform a wide range of tasks with precision and efficiency. Unlike fixed automation systems, robot arms can be easily reprogrammed and reconfigured. Their flexibility allows manufacturers to integrate them into existing manufacturing processes while maintaining the agility to handle diverse product variations and packaging needs. Collaborative Robots (Cobots): Cobots are designed to work alongside human operators. By combining the strengths of human workers with the precision and repeatability of robots, cobots enable manufacturers to achieve greater flexibility and efficiency in their operations. These collaborative robots can easily be redeployed to different tasks or production lines, making them ideal for dynamic manufacturing environments where adaptability is crucial. Automated Guided Vehicles (AGVs): AGVs are autonomous vehicles equipped with guidance systems, such as lasers or magnetic strips, that enable them to navigate manufacturing facilities and transport materials or products between different locations. These versatile robots can be programmed to follow predefined routes or respond to dynamic changes in their environment, making them ideal for material handling and logistics tasks. By automating transportation processes, AGVs enhance efficiency and flexibility in manufacturing operations, allowing for seamless integration with other automation technologies. The future of manufacturing lies in flexible automation. With advancements in technologies like robot arms, cobots, and AGVs, the industry is poised for growth. By integrating these solutions, manufacturers can eliminate the need for high-precision automation and adapt a more cost-effective and agile approach to production. Flexible automation has the potential to unlock new levels of productivity and competitiveness, shaping the future of manufacturing for years to come. You can learn more at info@southie.com .
What Does Your Copack Operation Have In Common With A Disney Movie? I’ve learned that it pays to be friends with the maintenance department.. My phone’s contact list has as many maintenance people in it as operations managers. That’s from lessons learned - in contract packaging and manufacturing. Why? They know stuff. They will find answers. They get things fixed. They also know equipment. What works well as well as what are the dogs. And that was the reason I was reconnecting with Isaac. I wanted to talk about robots in co-pack. (Not his real name. He’d say “You CAN use my real name. The bosses know I’m a straight shooter.” And he is. But I can’t help feeling that I need to make sure when we finish talking, he’s still in the best standing and gave me an unfiltered “voice from the production lines”. With labor shortages and the price of robot arms aligning favorably, plus some suppliers making the cost of an arm the same per month as a worker takes home in paychecks (through a Robot-as-a-Service RaaS model), I figured that Isaac would have some experience. Me getting unfiltered and straight shooter style instead of just points from a website’s sales pitch. All operations in contract packaging (or manufacturing) have “boneyards”. You may have seen pictures during the pandemic when airlines lost more than half their business, they stored 737s in a boneyard in a desert (that here in 2023 you are probably now flying in again). Why? It’s surplus to be reused or recycled or scrapped. In every co-pack operation I’ve visited there are boneyards, holding areas, surplus equipment areas or other named parking places. Some small, some big. Given the high mix and constant changeover needed in secondary packaging these are essential. A cartoner might not be needed on Line #6 today, but the weekly schedule says it needs to be set up by the second shift Friday. The place can also be the equivalent of a junk drawer. Think of it as “MacGyver is alive and well - he’s just wearing a maintenance shirt”. Some pieces are there to be taken apart and their components go on to help with some process improvements. A bigger motor on that conveyor will pull the weight of a belt struggling under twenty cases of detergent. Kind of an “organ donor” scenario. And Isaac and his creative team have done their share of transplants. It's also where bad ideas go to die. Picture it as the opposite end of the spectrum as a PackExpo – where the latest greatest newest ideas in equipment are there for people to see and envision on their production floors. All are good --- the trick is figuring out are they good for YOU? A new Tesla model 3 is pretty good technology…but if you are the one taking three kids and their three friends to soccer practice twice a week, you’re going to need a third row vehicle to be “good for you”.) A new piece of equipment that doesn’t cut it on the co-pack floor will find itself parked back in the boneyard. There you can find “do not touch” investments made by well-intended engineers or under informed decision makers. Accounting says to depreciate it for five years but you discover in year one it was a bad choice…with a price tag in the many thousands and at annual asset list review time you’ll need to answer: “What’s it going to take to get rid of?” (Well, you’d have to find a buyer. A buyer in the used equipment market, and one that is in your type of business, that happens to be looking and happens to have an approved budget and will probably offer half or less of your remaining book value. Then you have to convince the accountants that it’s OK to take a loss. (spoiler alert – it won’t be OK). Then somebody starts talking about who made this decision. It's not the latest mystery on Netflix but can turn into the co-pack version of “Knives Out”. Which is what I was asking Isaac about. The innovators leading successful contract packaging companies have already started using robot arms on their lines or are one budget away from doing so. They get it. The labor shortage isn’t going away. Workers have better choices now and they are making them. Repetitive jobs like placing products destined for a large retailer’s shelves onto conveyors to be shrink wrapped into “buy one get one free” packs for forty plus hours a week are going unfilled as wage battles get fought at distribution centers clustered around every other interstate cloverleaf in the US. There will be no influx of new or future citizens (and line workers) to surge and cover any unemployment deficits. Isaac knows that. He’s short by two maintenance techs to cover two shifts (three at peak season every Fall). That means constant juggling to keep what lines that are staffed running. Running and making money. Copack executives are finding it an interesting “IF-THEN” exercise. IF I don’t automate to close these gaps THEN I need to accept that my lines will be understaffed. IF they are understaffed THEN I need to slow them down. IF I slow them down THEN I miss deliveries or miss my profit targets for that SKU. IF I miss deliveries THEN customers will play the “next co-packer up” game and my revenue drops. IF I lose customers or profit THEN… Well, that’s usually when reality or good logic show that investing in technology like robot arms is the best approach today. Back to the front lines – and Isaac. He wants to know what’s on my mind (and I know that he is multi-tasking as we speak. Paying attention but also eyeing the floor and spotting an unexpected red Andon light telling him he might be getting paged if it doesn’t flip to green in the next couple of minutes). “Robots.” I say. And so I ask him, “Has your boneyard added any robots in the last year or two?”. I heard the chuckle before he said. “Luckily, no. But we came this close”. “Really? What happened?”. And then it was my turn to smile as I listened to a story I’ve heard too many times in the last few years from co-pack operations. Short version goes like this: Getting a robot WAS the right decision. But the choice of who to work with was not. All robot arms look great on the website video or in the convention center hall. The aisleway math done at the show booth made sense. Their co-pack operation could make X$’s more if missing positions were filled, they could run extra shifts, save OT etc. Enough to hit the payback period and ROI to keep financial folks happy. But what many find out (too late – after installing and running under longer real world conditions) is that the CHANGEOVER costs can kill all the positives about the new technology over on Line #3. Face it. Most co-packers are lucky to have a minority of lines running all but the same product night and day. Little or no changeovers (or once a month). The other lines? That’s life in co-pack: production runs that last under a full shift. A stream of SKUs next up. All short run high mix. As Isaac explained “Not the kind of work that can just sit and wait.” “Wait for what?” I asked. “Me. Or my team. If the robot needs a techie like me or even an engineer then it’s going to wait till we’re available. And then wait some more. Many don’t tell you it may stretch to hours for that to happen and then the time for us to program in all the parameters, test it out, rinse repeat.” “So, you passed on the robot arm?”. “Yep. For now.” My turn to smile again. “Isaac, that is more common out there than you would think. But there is one company I’ve run across that has delivered on making changeover in a matter of minutes not hours. And often with floor leads using the tablet, not you or your team of techies”. We spent a few minutes talking about Southie Autonomy. Their system is tailored for contract packaging floors and runs on any brand of robot arm – your choice or have them recommend. And the integrated camera that sees product coming to it – no need to add in more hidden costs for complicated fixtures and chutes to get it exactly in one spot and only one spot for the robot to grab. Isaac said thanks. I knew he was thinking about that red Andon light. I also knew he’d be looking up Southie on his lunch break, no doubt. The good thing is his company really does respect him and his people. And if it says it’s a good thing to consider, then it is. “Oh, one more thing.”, Isaac said. “Back to your first question. Yes, we did add to the boneyard. We added a Bruno”. I thought hard. “Bruno? Bruno?…”. I know most equipment companies out there in co-pack. But new ones emerge every day. I drew a blank and asked him to tell me about “Bruno” and why their technology ended up parked in his boneyard. “It’s not actually a company. Bruno is just what we call it.” And paused. For effect. “We don’t talk about Bruno, no, no, no!” (That song. It immediately came back to me. If you don’t have a young person in your life who has sung it a hundred times from the back seat on a road trip, look it up. It’s from the Disney movie “Encanto”. Catchy but kids have been known to sing that line over and over until the adult in the room or SUV distracts, bribes, does whatever it takes to stop it.) Before I could ask he continued. “Yeah we don’t talk about Bruno. On once a year executive visits there’s a tarp over it. Like a few others, it's best to just not talk about the money spent on a piece that just didn’t work out. Makes things uncomfortable. Hey. I gotta go”. And that’s what you are left with as you look at your co-pack operation. You will be considering robots. I’ll take that bet. Copack is made for using these to supplement their workforce. The forward thinkers are testing or installing now and many more to follow. Just be sure to include a call to Southie if you do look into robot arms for your packaging or even manufacturing lines. You don’t want to buy any Bruno’s. John has spent over thirty years learning in global manufacturing, automation, engineering, 3PLs and contract packaging. Currently still learning and sharing best practices in those fields and as an advisor to Southie Autonomy out of Boston MA. You can learn more at info@southie.com .
The Two Biggest Mistakes People Have Shared About Buying A Robot For Contract Packaging Only two? No, sorry to say, there’s more and those will be shared in another post. But for now, here in 2023 are the top two things that I have heard when talking to people in the industry: that if you figure out BEFORE you issue a PO for that new robot (or robots) on your contract packaging line you will be ahead of the game. Here’s the setting. The two of us are out on the co-pack floor standing at one of just under twenty lines. The products are typical of what you’d see at most standalone co-packers that serve many customers, or one that’s embedded in some large Fortune 100 CPG. Things you’ll be picking up on your next trip to Target or CVS or any other chain. Fresh from the factory, being re-packaged in the form that the consumer will notice, grab off the peg hook and toss in the cart. We are looking at his latest purchase – a robot arm. He is the site manager. Has been in co-pack awhile. We are on the production floor with about ten of those lines in full swing mid first shift. Conveyors, shrink wrappers, cartoners, clamshell sealers humming away in a blend of people and technology. I vaguely remember a P.J. O’Rourke quote (that I had to look up after as I write this) that came to mind: “Technology is dominated by two types of people: those who understand what they do not manage, and those who manage what they do not understand”. This guy is good, but today he had the look of the second type – shaking his head after admitting he was trying to make work some technology that he wished he’d understood better when he was on the floor of the last PackExpo in Chicago and decided to buy. He was wishing he’d have understood better what needs to happen in between production runs. I had a brief flashback. Sixteen-year-old me. First year of part time work and finally I thought I could get my own car with the money from that after school job. I had one picked out – front row of the lot (not a big dealer but the place with a trailer and a dozen cars or so.) My dad had stopped in to look at on his way home from work. Long story short – he was trying to tell me that I need to consider a few things it would most likely need and I’d have to pay for after I drove it off the lot. Things I hadn’t thought about - the hidden costs. Had I been in a job interview I’d have described myself as “Persistent. Confident”. My father would’ve described me differently. I was relentless and a pain. But he also knew I’d never learn and wasn’t listening, so he let me buy it. A week after driving it he and I were in the driveway replacing rear brakes. (Thankfully running a tab for me for the parts. His labor was free-ish. I was a captive audience for some thinly veiled “I told you so’s” as my payment.) Two weeks later the pinkish spots on the street where I parked had turned to a puddle and I learned that transmissions have fluid. Need fluid actually. And at the rate mine was bleeding out it could end up being parked there for a long time. Back to the co-pack floor as he opened up. “I do read the posts. I know that packaging people like me are working hard to figure out this labor gap. It hurts to see the economy steaming along and the volume that’s there for the taking, but I don’t have the people to do it. I also see that some of my peers, and competitors, are already adding robot arms into their lines. It makes sense. I don’t need to have all fifteen or so slots on this line automated. But if I can add in one or two arms on an understaffed line, I just raised my line productivity ten or twenty percent. And my capacity. And my bottom line gets better.” “Agreed.” I said. “So, this robot arm that’s not running now, when can I see it in action?”. “Tomorrow. Probably second shift”. “Mechanical issue? Broke down already?” “No, never had a breakdown yet. It runs well. It really does …WHEN it runs”, he told me. “So why not now?”. That’s when he shared the two things he wished he’d paid better attention to: time and skill level to changeover. “When I was at the show I should’ve dug deeper into programming time. We change SKUs on a line once or twice a shift. High mix is our world. On top of that the consumer packaging seems to change every few months – marketing keeps the look fresh but often that means I can’t just pull up from the saved library that SKU…it’s brand new. It’s faster than years ago, I get it. But for our products it still can take hours. If I could hire enough people, then the person in that spot I could train to do the task in minutes. That’s what I need from this robot…minutes not hours.” Across the aisle I saw his maintenance lead deep into what is called “unscheduled downtime” on the end of shift reports. Something stopped. And a dozen plus people standing idle until he and his team can fix it is making the site manager pay attention to that while we talk. “And that’s the other reason this robot is doing nothing right now. I need one of the maintenance team to get freed up and dive into the tablet to set up the robot arm’s next SKU. They are the highest skilled in the building, but I need them first to keep the floor running. So, there are times on a line where I have the product, the equipment and the due date hanging over my head… but I’ll be a shift or two behind because I need the robot programmed by a tech. What’s my choice? Let that line sit and all those people standing while he gets this one ready?”. He had a few other “lessons learned” but when I asked what he’d tell someone in his same shoes looking into adding robot arms to co-pack lines at their sites he said, “Do it. You don’t have a choice. After you get comfortable with the first couple, you’ll be adding robots into your next year’s budget like they were conveyors – just standard equipment that you need. Just be sure you pick one that can be programmed by people like a floor lead and not need an engineer or maintenance lead. And keep looking till you find someone that sells robots that can show you changeover times in MINUTES. I’m sold on robots. We’ll keep using this one. But I’m looking at better choices for the next one.” He wrapped things up with this. “Contract packagers live in a high changeover world. You always hope that the sales team will land that contract or you get that “big fish” order of one single part number that runs on one or two of your lines non-stop, day after day. But the reality is what you see here. Shortest changeover and the ability to have that changeover programming done by more people on your floor, well then technology like robot arms will let you make money and hit due dates.” “Make money and hit due dates”. That’s a way better mission statement than I’ve seen posted in many site lobbies. If you are looking for a robot solution for your co-packing operation – look at Southie Autonomy’s offerings. They have been using AI before artificial intelligence was being mentioned, it seems, in everyone’s marketing info here in early 2023 (It should remind you of when the iPhones, iPads, iPods, iTunes first came out and everybody’s product seemed to be being rebranded with an “i” in front of its name (looking at you iHeartRadio, iRiver, iRobot and many more). It matters because Southie’s solution, placed on any brand’s robot arm, does allow for changeover programming to happen in minutes. It does allow for a line lead to do it (vs a maintenance tech or engineer). You can contact them to learn more at info@southie.com. Unless you don’t want to “make money and hit due dates”. John has spent over thirty years learning in global manufacturing, automation, engineering, 3PLs and contract packaging. Currently still learning and sharing best practices in those fields and as an advisor to Southie Autonomy out of Boston MA.
From Concept to Carton: Robotics' Role in Transformative Co-Packaging Robotics integration into co-packaging represents a significant advancement, focusing on operational efficiency and precision. In 2021, a historic peak was reached with 517,385 new robotic installations globally, underlining a widespread shift towards automation. This development serves as a critical bridge, converting innovative design ideas into tangible packaging solutions. The packaging robots' market, valued at over USD 4 billion in 2022, is on track to expand at a CAGR of over 10% between 2023 and 2032. This growth is fueled by the efficiency, minimal maintenance, and longevity of packaging robots, leading to improved product quality and customer satisfaction. In this blog, we will explore the multifaceted role of robotics solutions, from transforming assembly lines to enhancing quality assurance. We’ll see how robotics is not just automating tasks but redefining packaging, bringing a blend of precision, innovation, and efficiency to the industry. The Robotic Assembly Line: Turning Concepts into Co-Packaging Reality Robotic assembly lines stand as a cornerstone in the co-packaging industry, turning concepts into reality. This process is marked by a series of critical steps where the advantages of robots, coupled with the synergy of technology and innovation, come to life. Let’s delve into the key aspects that highlight how robotics play a crucial role in materializing packaging concepts into reality: Design to Execution: Robotics efficiently convert detailed design plans into accurate physical packaging. This transition from digital blueprints to tangible products is critical in realizing conceptual ideas. Advanced robotics solutions can interpret complex design parameters, ensuring that the final packaging faithfully reflects the envisioned concept. Customization Capabilities: Robotic systems are programmed to handle a wide range of packaging designs, accommodating various sizes, shapes, and materials. This flexibility is essential for bringing diverse packaging concepts to life, allowing for quick adaptations to new designs without extensive manual reconfiguration. Scaling Production: One of the major strengths of robotics in co-packaging is the ability to rapidly increase production volumes. They can move products up to 20ppm and can work for around 70,000 hours (about 8 years) at a stretch. This scalability transforms small-scale concepts into large-scale productions efficiently, enabling businesses to meet market demands without compromising on the quality or fidelity of the packaging design. Integrating Innovations: As packaging concepts evolve, incorporating innovative materials or unique structural designs becomes crucial. Robotics solutions are adept at integrating these new ideas into the production process, ensuring that even the most avant-garde packaging concepts can be realized effectively and efficiently. Enhancing Product Handling: Handling delicate or intricately designed products can be challenging. Packaging robots excel in this aspect, packaging these items with high precision and care. This ensures that the product remains intact, and that the packaging concept’s integrity is maintained from start to finish. Quality Consistency: Consistency is key in co-packaging, especially when dealing with large volumes. Robots maintain stringent quality standards across all units, ensuring each package is a true representation of the original concept. This consistency is vital for brand image and customer satisfaction, as it guarantees that every product meets the conceptualized quality and appearance standards. Quality Assurance in Action: Robotics' Continuous Monitoring Robotics integration in co-packaging not only streamlines production but also plays a pivotal role in maintaining high product quality. This is achieved through a combination of advanced technologies and precise operational capabilities. Here's how robotics solutions contribute to robust quality assurance in co-packaging: Continuous Inspection: Equipped with advanced sensors and high-resolution cameras, robotic systems continuously scrutinize products on the assembly line. This enables the detection of any deviations or defects almost instantaneously, allowing for prompt corrective actions. Precision in Repetition: Unlike human labor, robots can perform highly repetitive tasks with unwavering precision. This uniformity is crucial in maintaining consistent quality across all products, regardless of production volumes. Data-Driven Adjustments: Throughout the packaging process, robots collect and analyze data. This information is crucial for making real-time adjustments, optimizing the production process, and maintaining a high standard of quality. Minimal Human Error: Automation significantly reduces the risk of human error, particularly in tasks that require high consistency. Robots execute these tasks with a level of accuracy that is challenging to achieve manually, leading to fewer quality issues. Efficient Feedback Loop: Robotic systems are often integrated with rapid feedback mechanisms. These systems enable immediate identification and correction of any issues, ensuring that the final product consistently aligns with the set quality standards. As we conclude, it's clear that the robotics integration in co-packaging is not just a technological upgrade, but a strategic shift towards smarter, more efficient production. Packaging robots are not just tools; they are collaborative partners that bring precision and innovation to the forefront of packaging. This evolution marks a new era where technology and human ingenuity join forces to create practical and groundbreaking solutions. The future of co-packaging, shaped by robotic advancements, promises not only enhanced efficiency and quality but also a platform for continuous innovation and growth in the packaging industry. https://www.linkedin.com/pulse/revolutionizing-industries-growing-role-packaging-robots-steve-jason/ https://automation.omron.com/en/us/blog/top-six-trends-shaping-packaging-industry-today https://www.robotics247.com/article/robots_edge_into_packaging https://www.cyberweld.co.uk/robotics-in-the-manufacturing-industry https://robotsdoneright.com/Articles/how-industrial-robots-improve-product-quality-in-manufacturing.html https://howtorobot.com/expert-insight/quality-control-robots-ensuring-excellence-manufacturers https://utilitiesone.com/the-role-of-robotics-in-enhancing-manufacturing-efficiency
The User's Voice: Shaping the Future of Humanized Robotic Interaction In robotics, the significance of human robot interaction (HRI) is increasing constantly with focus on a more empathetic and effective communication between humans and machines. In this blog, we will explore how user feedback is integral to refining robotic systems and their behavior, making them more intuitive, responsive, and aligned with human needs and emotions. We will discuss how ongoing feedback, personalization, and user-centric design are enhancing the functionality of robots and enriching the human experience with them. By exploring these key aspects, we will get a glimpse into a future where robots are not just tools, but empathetic, adaptive partners in our daily lives. User Feedback Loops: Iterative Improvements in Robotic Interfaces With the help of user feedback loops, robotic systems are not just becoming technologically advanced but also accustomed to human interaction. This ensures that as robotics progress, they do so with a deep understanding of human sentiments. Let’s explore the critical role of continuous feedback in refining human robot interaction: Iterative Learning and Adaption: Robots evolve through ongoing user feedback, mirroring the human process of learning and adapting. This continuous cycle of receiving and incorporating feedback enables robots to progressively refine their algorithms and behaviors. It ensures their actions and decisions are increasingly in sync with user expectations and real-world scenarios. Error Identification and Correction: Regular feedback helps pinpoint and fix errors in robotic systems, enhancing their reliability and functionality. By analyzing user interactions and responses, robots can identify discrepancies and malfunctions in their operations. This continuous process of error detection and correction not only improves the current performance of robots but also informs the development of more robust and error-resilient systems for future applications. User-Centric Design Philosophy: Feedback loops facilitate the personalization of robotic interfaces, increasing user satisfaction and engagement. These loops also ensure that robots are accessible and user-friendly, accommodating a broad spectrum of user needs and abilities. Refinement of Communication Methods: User feedback on non-verbal interactions allows robots to better understand and react to human gestures and facial expressions. Continuous input on voice interactions aids in the improvement of speech recognition capabilities, making conversations with robots more fluid and natural. Predictive and Context-Aware Adaptations: Analyzing feedback helps robots anticipate user needs and preferences, leading to proactive behavior modifications. Feedback is crucial in developing context-aware responses, enabling robots to adjust to different environments and situations effectively. Personalization in Robotics: Tailoring Experiences to User Preferences The journey towards personalizing advanced robotics is not just about technological innovation. Instead, it represents a shift towards creating more empathetic, responsive, and user-friendly machines. Let’s see how adapting robotic systems to align with individual user needs is beneficial: Customization of User Interfaces: Robots are being designed with adaptable interfaces that can be tailored to individual preferences, ranging from language settings to interface complexity. This customization allows for more intuitive interactions, particularly important for users with specific accessibility requirements. Adaptive Learning Algorithms: Robotic systems are increasingly equipped with algorithms that learn from user interactions, enabling them to adapt their responses and actions according to individual user behavior patterns. This continuous learning process ensures that robots remain relevant and efficient in meeting evolving user needs. Recognition of Individual Preferences: Advanced sensors and data analysis enable robots to recognize and remember individual user preferences. These include preferred temperatures in smart homes to packaging tasks on a manufacturing production line. This recognition leads to more personalized and satisfying user experiences. Emotional Intelligence in Robotics: Incorporating emotional intelligence allows robots to respond to the emotional states of users, adapting their behavior to provide comfort or assistance as needed. This aspect is especially crucial in healthcare and therapeutic settings, where personalization can significantly impact the effectiveness of treatment and care. Feedback-Driven Personalization: User feedback is continuously analyzed to refine and enhance the personalization features of advanced robots, ensuring they evolve in tandem with user expectations. This approach fosters a deeper bond between users and robotic systems, making them more than just tools, but companions that understand and grow with their users. Context-Sensitive Adaptations: Advanced sensing and AI enable robots to understand and respond to specific context of their interactions. This adaptability allows for assistance based on the environment, task, and user’s state. Such context awareness in robotics leads to more intuitive and appropriate responses, enhancing the overall user experience. As we look forward to the future of human robot interaction, the key to success lies in understanding and responding to the user. The advancements we see today in personalization and feedback mechanisms are just the beginning. Tomorrow's robots will be even more in tune with our needs, offering tailored assistance that goes beyond mere functionality. They will become an integral part of our daily lives, not only as tools but as intelligent companions that grow and evolve with us. This future, rich with possibilities, promises a new era where technology and humanity converge in the most seamless and enriching ways.
Beyond Assembly Lines: Navigating the Robotic Revolution in Co-Packing Robotics integration in co-packing industry has marked a significant shift from traditional assembly lines to automated packaging. The global packaging robots market is projected to grow at a CAGR of over 10% from 2023-2032. This growth is propelled by numerous benefits that robotic systems in packaging industry offer. These include efficiency, reduced maintenance, and increased capacity for high-speed operations for extended hours. Robotics revolution in co-packing is not just about automation. It’s a strategic response to industry challenges like rising labor costs and the need for precision and consistency in packaging. Moreover, companies implementing robotics have seen cost savings of up to 20%, a figure anticipated to reach 22% by 2025. This transition is not without its challenges. However, the long-term benefits, including operational efficiency outweigh these initial barriers. As we delve deeper into this topic, it's clear that the robotic revolution in co-packaging is not just about replacing human labor but about reshaping the landscape of manufacturing and packaging for a more efficient, precise, and sustainable future. Rise of Robotics: A Catalyst for Change Following factors are collectively influencing a transformative era in co-packing, where robotics is not just an option but a necessity for growth, innovation, and sustainability: Advancements in Technology: The continuous development in robotics technology, including improvements in AI, machine learning, and sensor technology, is pivotal. These advancements make robotics solutions more efficient, adaptable, and capable of complex tasks. Labor Market Dynamics: Scarcity of skilled labor and the challenge of repetitive or hazardous tasks in packaging industries drive the adoption of robotic systems. Robotics offers a way to mitigate these labor issues while maintaining production efficiency. Economic Drivers: Economic factors, such as the increasing cost of labor and the need for cost-efficient production methods, are significant catalysts. For instance, in 2021, the robotics industry witnessed a historic peak with an estimated 517,385 new robotic installations globally, indicating a significant shift towards automation in response to economic and labor market conditions Demand for Precision and Consistency: In the co-packing industry precision and consistency is crucial and robotic systems offer unmatched accuracy and uniformity in packaging, which is hard to achieve manually. Sustainability and Waste Reduction: The push towards sustainability has become a major driving force. Robotics solutions can help in reducing waste and optimizing resource use in packaging processes. This actively aligns with the global trend towards more sustainable practices. Integration with Industry 4.0: The trend towards smart factories and integration of IoT, data analytics, and connected systems in manufacturing processes are complemented by the robotic revolution. This integration enhances overall productivity and supply chain efficiency. Efficiency Redefined: Robotics Beyond Traditional Assembly Lines Transformation in the co-packing industry driven by robotic revolution leads to unprecedented levels of efficiency, quality, and productivity, paving the way for innovative and cost-effective solutions in the future. The following are ways in which the rapid adoption of robotic systems is taking the packaging industry beyond traditional assembly lines: Automated Pick and Place: Robotics solutions equipped with advanced vision systems revolutionize pick and place operations. They can handle products with speed, accuracy, and consistency. Packaging Line Integration: Robotic systems integrate seamlessly with various stages of the packaging process, enhancing workflow and minimizing downtime. High-Speed Sorting and Packing: Robots excel in rapid sorting and packing applications, ensuring precision and minimizing wastage. Quality Control and Inspection: Vision-guided robotics solutions in packaging enable sophisticated quality control, detecting defects, and ensuring high-quality output. Flexibility and Scalability: Robotic systems can be reprogrammed for different product sizes, shapes, or packaging formats. Hence offering adaptability to market demands. Worker Safety and Ergonomics: Automation of repetitive, physically demanding tasks reduces injury risks and improves workplace well-being. Data Analytics and Optimization: Robotics in packaging gather extensive data for analytics, helping optimize processes and improve decision-making. Beyond Assembly Lines - Embracing the Future of Co-Packaging with Robotics These future-oriented developments are set to revolutionize the co-packing industry, bringing unprecedented efficiency and innovation. Developing Smart Packaging Systems: Emphasis on creating packaging systems that are not only automated but also intelligent, capable of real-time decision-making and adjustments. Extended Reality Applications: Utilizing augmented and virtual reality in co-packaging for training, simulation, and enhancing the human-robot interface. Robotics as a Service (RaaS): Growth in RaaS models, offering flexible, cost-effective access to advanced robotic systems for businesses of all sizes. Nanotechnology in Robotics: Incorporating nanotechnology for more precise and efficient packaging processes, especially in sectors requiring extreme precision. Energy Efficiency and Green Robotics: Innovations leading to more energy-efficient robots, aligning with global sustainability goals. Predictive Maintenance Through AI: AI-driven predictive maintenance to reduce downtime and increase the lifespan of robotic systems in co-packaging. The future of co-packaging, backed by robotic revolution, promises to enhance operations and redefine packaging. And as we stand on the brink of a new era in co-packing, the integration of robotic systems paves a transformative journey. This evolution transcends traditional methodologies, bringing in an age where efficiency, customization, and sustainability are realities. https://www.wevolver.com/article/what-are-robotic-assembly-lines-history-components-advantages-limitations-applications-and-future https://alp.consulting/robotics-in-manufacturing-industry/ https://www.packworld.com/machinery/robotics/article/22869401/innovations-in-packaging-robotics-address-labor-crisis https://aithority.com/guest-authors/robot-revolution-how-is-packaging-needing-to-adapt-for-the-droid-generation/ https://blog.drupa.com/en/how-the-robotics-technology-revolutionizes-packaging/
Precision Packaging: How Robotics Revolutionizes Co-Packing Operations The growing complexity and diversity of products in today's market make it imperative for manufacturers to adopt a more advanced approach to packaging. Precision packaging, with its focus on meticulous design and quality control, ensures that products are safeguarded with utmost accuracy. In this landscape, embracing robotics integration with co-packing operations is enabling manufacturers to meet the evolving customer expectations. One of the significant advantages of robotics solutions is in their ability to blend effortlessly into existing packaging lines while occupying minimal space. With the packaging robots market size expected to grow at a CAGR of 10.8% between 2023-2030, manufacturers are realizing that this integration extends beyond being a mere technological upgrade. It's a strategic enhancement that caters to the growing demands for complex packaging designs and customization, simultaneously boosting overall productivity. Robotic Technologies in Co-Packing The packaging robots market is expected to exceed $15.73 billion by 2030, driven by the transformative impact of robot technology on co-packing operations. Here's a look at some of the key technologies driving this transformation: Collaborative Robots (Cobots): It is anticipated that by 2025, collaborative robots will make up 34% of the total industrial robots sold, thereby highlighting their growing popularity. Working collaboratively with human operators, Cobots bring a harmonious blend of automation and human skills to co-packing. Articulated Robots: Renowned for their flexibility, articulated robots emulate the range of motion of a human arm. This adaptability proves crucial in co-packing scenarios where diverse packaging formats and product specifications require careful handling. SCARA Robots: The adoption of SCARA robots is fast increasing and is expected to reach a market size of $14.8 billion by 2026. This is mainly because of their high speed and precision. These robots excel in pick-and-place applications. Their horizontal reach and rapid movements make them ideal for tasks demanding swift and accurate packaging. Delta Robots: Distinguished by a parallel linkage mechanism, Delta robots boast exceptional speed and precision. Their rapid operation is particularly advantageous in high-throughput co-packing, ensuring efficiency without compromising accuracy. In addition to these technologies, the integration of artificial intelligence (AI) is playing a crucial role in improving the efficiency and intelligence of these robotic systems. AI enables these robots to learn from their environment and make autonomous decisions, further streamlining the co-packing process. Advantages of Precision Packaging with Robotics Robotics integration in precision packaging offers a multitude of advantages that significantly enhance the co-packing process. This is evident in the current landscape, where nearly 84% of packaging companies are already using robotic technology. Here are some key advantages: Increased Speed and Efficiency: Robots dramatically increase the speed of packaging processes. They are designed to operate continuously without fatigue, leading to higher throughput and faster turnaround times. This efficiency is essential in meeting the demands of high-volume production schedules. Enhanced Precision and Accuracy: Robotics solutions bring a level of precision to packaging operations that are challenging to achieve manually. The accuracy of tasks such as product placement, labeling, and quality control is significantly heightened, ensuring consistently flawless outcomes. Cost Efficiency: While the initial investment in robot technology may be substantial, the long-term cost efficiency is undeniable. Packaging robots streamline operations, minimize errors, and reduce the need for manual labor. This ultimately leads to lower operational costs by up to 20%. Adaptability to Varied Products: The versatility of robotics solutions allows for seamless adaptation to diverse product types and packaging formats. Whether handling fragile electronics or intricate pharmaceuticals, packaging robots excel in accommodating the unique requirements of each item. Workplace Safety: Collaborative robots enhance workplace safety by up to 28% by working alongside human operators. This mitigates the risk of injuries and fosters a collaborative environment where human skills and robotic precision complement each other. Integration Strategies for Co-Packers Successful robotics integration into existing co-packing operations requires strategic planning and execution. Here are key strategies for co-packers: Conduct a Thorough Assessment: Begin by evaluating current packaging processes, and identifying areas where robotics solutions can offer the most significant improvements. Understanding the specific needs and constraints of the existing operation is crucial for smooth integration. Choose the Right Robotics Solutions: Select robots that best fit the identified needs. Consider factors such as the size of the operation, the nature of the products, and the specific tasks to be automated. Employee Training and Involvement: Invest in training employees to work alongside the new robotic systems. Ensuring that staff are knowledgeable and comfortable with robot technology enhances efficiency and fosters a collaborative environment. Gradual Implementation: Introduce robotics gradually rather than all at once. This approach allows for adjustments and fine-tuning, minimizing disruption to existing operations and reducing the risk of significant downtime. Regular Maintenance and Updates: Establish a routine for maintaining and updating the robotic systems. Regular maintenance ensures optimal performance and longevity, while software updates can provide new features or improvements. While robotics integration into co-packing operations presents its challenges, the long-term benefits far outweigh these initial hurdles. The accuracy, speed, and flexibility offered by robotics solutions meet the current demands of packaging and also anticipate future needs, adapting to changes with ease. Moreover, their contribution to cost savings and enhanced worker safety adds layers of value to their implementation. As co-packers deal with the challenges of combining technology and traditional methods, the benefits become more evident. This creates a balanced approach where precision is not just a goal but a standard for the future. https://www.cyberweld.co.uk/how-are-robots-used-in-the-packaging-industry https://mitsubishisolutions.com/make-way-for-more-flexible-responsive-packaging-robots/ https://www.packworld.com/robotics/video/22867711/explore-six-types-of-robots-that-are-revolutionizing-packaging-and-processing https://www.universal-robots.com/in/blog/impact-of-robotics/ https://www.rprobotic.com/the-booming-packaging-robots-market-revolutionizing-the-future-of-manufacturing.html