Checklist for the cobot strategy in the company Successful implementation of cobots

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reichelt elektronik GmbH & Co. KG

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With the help of cobots, companies can increase their productivity and flexibility. Even though cobots are very easy to use, there are still some challenges to overcome. The checklist from reichelt elektronik shows the steps to a successful implementation.

The trend is towards cobots: According to a recent survey by reichelt elektronik on the topic of automation, more than 45 percent of the companies surveyed plan to integrate cobots into their workflow in the next twelve months. They offer numerous advantages, such as an increase in production speed or greater flexibility in production. However, the introduction can also pose some challenges for companies.

"We recognized the potential of cobots some time ago, which is why we distribute versatile models from various manufacturers. However, before acquiring such cobots, there are some strategic considerations and prerequisites that must absolutely be taken into account to ensure successful use," comments Tobias Wölk, Product Manager for Automation Technology and Active Components at reichelt elektronik.

Goal definition and needs analysis

Before acquiring a cobot, clear goals should be defined and needs analyzed to optimally plan its use and measure future successes. Possible goals might include increasing production capacity, reducing costs, minimizing waste, or improving product quality. The first step involves taking stock of the status quo, analyzing the strengths, weaknesses, opportunities, and threats (SWOT) of the current production processes. Subsequently, the company should formulate specific requirements and expectations that must be met through the introduction of cobots.

Additional assistance in creating action recommendations and evaluations is provided by formulas for amortization: these allow decisions to be made on whether—and if so, in what scope and timeframe—investments should be made. The formulas aid in calculating how many raw materials the company can save in production with a cobot or how much manual rework can be avoided. Since the budget always plays a crucial role, the company should definitely research and utilize current funding for cobots.

Technical requirements: selecting a suitable cobot

When selecting a suitable cobot, several important factors play a role: The size and degree of collaboration of the cobot must match the specific task and available space, including any protective barriers. Will the cobot have a fixed place in the operation, or does it need to be mobile? The process's cycle speed should also be considered, as well as the required reach and the robot's mobility in terms of its degrees of freedom. The payload and error tolerance are also crucial in choosing the optimal automation solution.

Suitability test: a pilot project in theory

After the company has chosen a cobot model, the suitability test follows as an essential step for successful implementation. This method ensures both successful integration and enables the identification and minimization of risks for the cobot's work environment. The test includes:

• Task analysis: preparation of a specification sheet and recording of relevant performance data

• Examination of technical feasibility in terms of capacities as well as the know-how and training needs of the staff

• Creation of a technical concept: Cobot specifications, workplace requirements, necessary safety equipment, required logistics

• Final quick-check

The quick-check evaluates all application features in detail and ensures that relevant criteria such as flexibility, productivity, and safety requirements are met. If the quick-check reveals problems in the implementation of the application, the suitability test must be started from the beginning.

Risk assessment and safety measures

Before commissioning, all machines must be risk assessed to ensure there is no danger to employees. The risk assessment identifies and evaluates technical issues related to the design, function, operation, setup, maintenance, and servicing of the cobots. It also considers the accident history, observes regulations, standards, and significant hazards (especially DIN EN ISO 10218) as well as human factors in accordance with DIN EN ISO 12100:2010, 5.5.3.4.

The subsequent safety measures for risk mitigation are based on the identified hazards. This is best explained with an example: Imagine the cobot works on the production line assembling workpieces. The risk assessment shows that there is a crushing hazard for the product during processing and for the employees when removing the finished workpiece. To avert this danger, sensors are implemented to monitor force impact. They signal the cobot when a predefined threshold value is exceeded. Rounded edges on the grippers further minimize the risk of injury.

Preparation for the system integration of the cobot

Now comes the exciting part: The cobot is to demonstrate its capabilities in a pilot project. For this, it is essential that employees undergo training that informs them about new work and production processes and prepares them for changes in occupational safety, ergonomics, and data protection. Additionally, employees may need to adjust their own work processes if a cobot takes over tasks or accelerates certain processes.

The cobot must also be "trained" for its new task. Programming for these robots is done either through manual hand guidance or graphical tablet interfaces. The advantage of these methods is that the training time is significantly reduced. The operator learns programming faster—even without specific programming knowledge. This allows the cobot to be used in daily operations more quickly.

Back to the example of the cobot in the production line: During the test phase, its movements are monitored and repeatedly adjusted to ensure maximum efficiency, precision, safety, and intuitive operation. By the end of the pilot project, which may take a few weeks to several months depending on the complexity, the cobot should be optimally integrated into the production environment and significantly improve productivity.

Continuous monitoring and regular maintenance for optimal performance

After the pilot project has been successfully completed, the cobot is ready for daily use. Regular monitoring of performance and operating parameters ensures that the cobot functions flawlessly. Feedback loops, provided by users, ensure that weaknesses are identified and the system can be adjusted if necessary. This also ensures the continuous adaptation of the cobot to changing requirements.

In addition to monitoring, maintenance is also essential for the cobot, which, like all other machines, must be serviced regularly. The maintenance work includes, among other things, checking and, if necessary, replacing wear parts as well as updating the software to implement safety and performance improvements.

Making the right decision

With this checklist, companies can ensure that no important points are overlooked in the purchasing decision. However, theoretical considerations do not replace practical testing. Companies that are still looking for the right solution or have not yet decided whether a cobot is right for them can get an idea of the latest models and gather valuable information at trade fairs. These include the SPS in Nuremberg and the Hannover Messe (both located in Germany).