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PROCESS AUTOMATION


Carl Patrick, Robot Sales Manager – Machine Tool Automation, FANUC UK, busts seven myths


surrounding automation and robotics


SEVEN REASONS TO EMBRACE ROBOTICS T


he UK is currently the world’s sixth largest economy and eighth largest manufacturing nation1


. But there remain


concerns around labour shortages and low productivity rates. These issues are – and always have been – linked to automation. In order to remain competitive, industrial companies need to produce more goods, to a higher quality and in less time. In every industrial revolution, automation has been proven to boost productivity. Yet whereas the UK was once the world leader in its adoption, we now rank a lowly 25th in the world for robot density, with 98 robots per 10,000 workers. Germany, the leader in Europe, boasts 4152


.


There are some signs of improved take-up, however; 2,534 new robots were installed in the UK in 2022 – 54% more than in 2015. But the productivity gap persists and reluctance to invest in automation is still a major challenge, especially among SMEs. Much of the lingering reluctance is around a long-held fear of automation, largely based on myths that are well past time for busting. Here, we counter seven of the most popular misconceptions: Myth #1: Automation solves everything Automation is not a magic bullet. If a manufacturer is looking to solve a bottleneck, then automating the process will just mean parts arriving at the bottleneck faster. And problems with quality and consistency won’t be solved simply by installing a machine. Instead, factory owners should seek advice from an automation expert, such as FANUC or one of our system integrator partners, about their exact needs and what they want to achieve. We can help to identify problems with existing processes and advise on how best to employ automation to deliver objectives. Myth #2: Automation is too complicated It really doesn’t have to be. Businesses can start small, with simple functions and progress from there. FANUC’s user-friendly software tools – such as FANUC Ladder III, FANUC PICTURE and C-Executor – feature command systems with drop-down menus and choice paths that look familiar.


Myth #3: Automation will replace valued employees


The right automation solution will replace 12 FEBRUARY 2024 | PROCESS & CONTROL


Myth #5: We lack the in-house skills to programme a robot


tasks, not people. The best way to approach a robotics project is to look at what is happening already and identify ways to do it better. Automating processes that are dull, dirty or dangerous helps reduce staff injuries and overcome quality issues born of boredom, freeing up employees to take on more value- added tasks. This can improve staff retention rates, boosting morale and positively impacting productivity.


Automation can also help to capture experienced employees’ expertise. A successful project will involve talking at length to the people who carry out the task and discussing with them how to do it better. This is particularly pertinent, given that almost one fifth of employees in the UK manufacturing industry is aged 55 or over, with 20% of the workforce set to retire within the next decade3


.


Myth #4: Why fix something that isn’t broken? Our current equipment has been working fine for decades…


Great! There’s no reason why embracing automation should require any company to ditch their current equipment, especially if it is working well. FANUC robots are regularly integrated into existing lines, complementing older machinery to enhance working practices and increase efficiency and boost productivity. What’s more, these modern alternatives are designed to last for decades. Older machinery can require more maintenance to keep it running, meaning more time offline. By contrast, advanced condition monitoring has almost completely eliminated unforeseen breakdowns and unnecessary part replacements in modern robotics, enabling longer service intervals and increased uptime.


FANUC software does not require in-depth knowledge of coding. Simple drop down ‘nesting’ menus with standard procedures and a range of Yes/No choices make today’s advanced automation systems far simpler and more adaptable, and can be programmed easily by in-house staff. In addition, we offer training, either at our UK headquarters in Coventry or at customers’ premises, as well as a dedicated after-sales support team.


Myth #6: Any automation system we install will quickly become obsolete


Robot technology and tasks, such as pick, turn and place, have been around for decades. What has changed is control software and the tools that can be attached to them. Robotic tools will last at least as long as ordinary tools but deliver far more value throughout their lifespan.


Myth #7: Automation is prohibitively expensive


The key here is only to buy equipment appropriate to need and to focus on the total cost of ownership, rather than the initial purchase price. By speaking with an experienced automation provider, manufacturers can ensure that their system is not over-specified, and that it will deliver a good return on investment.


The UK government is encouraging the purchase of capital equipment with annual investment allowances that enable machinery costing up to £1,000,000 to be fully offset against profits in a single year. And the rise in corporation tax means that tax reliefs are now even more valuable. In addition, a range of financing packages, including


https://www.themanufacturer.com/articles/uk- manufacturing-sector-climbs-to-eighth-in-world-rankin gs-make-uk-analysis/ 2


leasing, can spread costs. 1


IFR report, 2023 3


FANUC www.fanuc.eu/uk/en


ONS data


FANUC’s robots offer eight-year mean time between failures, while the CRX collaborative robot (cobot) series boasts eight-year zero maintenance.


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