Innovation | automation
Plastics manufacturers are installing more robots as they look to reduce cost, minimise energy usage and improve competitiveness, writes John Osborne
Economics and automation
The utopian vision of totally automated manufacturing operations where humans plan the tasks and robots do the work has, to date, not really been realised. But while few completely automated factories exist, the reality is that more and more robots are being installed worldwide – robots are simply much better suited to repetitive tasks than people, especially when extreme accuracy is required or heavy loads are involved. Data released this month by the International
Federation of Robotics (IFR) shows that global indus- trial robot sales reached their second highest ever level in 2012, exceeding 159,000 units. The automotive industry drove the growth, up by 6% on the previous year, while the plastics, chemicals and food sector also saw sales ahead. “Between 2008 and 2012 robot sales have increased by 9% on average per year. The demand for industrial robots is increasing due to the accelerating trend towards automation all over the world. We estimate that robot installations will reach a similar level again in 2013,” says IFR Industrial Robot Suppliers Group chairman Dr Andreas Bauer (Figure 1). One of the key points to come out of the latest IFR
data is that demand for industrial robots is growing in general industrial applications, as well as the tradi- tional automotive sector. According to the association, the trend towards automation is continuing due to the
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increasing industrialisation of large and growing consumer markets, the necessary modernisation of existing production facilities and the need to be competitive in a global market. Other key drivers include energy-effi ciency and the introduction and retooling for light weight construction technologies. Mike Badger, plastics segment manager for ABB’s UK Robotics business believes the increasing use of robots can be attributed to increased competition “coupled with spiralling energy and raw material prices”. He says these factors “are placing plastics manufacturers under growing pressure to fi nd new ways to reduce costs and improve their production processes. In many cases, these pressures are being further compounded by a severe shortage of skilled workers needed to boost productivity and effi ciency.” Few areas of the world can look forward to falling
energy prices. And energy investment planning in some countries risks lagging expected demand - manufactur- ers in the UK were recently warned by the Government they may need to reduce their energy consumption to prevent domestic blackouts in the future as a result of closure of ageing nuclear plant while the German government’s decision to abandon nuclear is also predicted to require substantial investment in alterna- tive generating capacity. “With supply being steadily outstripped by demand, it
July/August 2013 | INJECTION WORLD 21
Main image: Global
industrial robot installations
have grown by almost 10% a year since
2008, according to latest IFR data
PHOTO: ENGEL
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