It’s time to turn our attention to SMEs and the skilled labour sector! For several years now, there has been a noticeable increase in the use of human-robot collaboration (HRC) in German SMEs. The International Federation of Robotics (IFR) predicts that in future it will not only be large companies such as those operating in the automotive industry that will need robotics in order to operate competitively, but also a wealth of smaller companies. A development like this raises questions: What opportunities do these “cobots”—robotic arms that work collaboratively side by side with people—really offer, and how can SMEs best make use of them? Tobias Wölk, Product Manager Automation Technology & Active Components at reichelt elektronik, explains how the multitude of collaborative robotic arms is opening up new avenues of application for companies.
Why opt for a robotic arm now?
Manufacturers offer a wide range of robotic arms for a variety of tasks in medium-sized companies. Models suitable for simple pick-and-place tasks can even be procured for under EUR 5000. For more complex applications the prices range from EUR 25,000 to EUR 40,000. Although HRC systems involve acquisition and installation costs, after successful implementation they also generate revenue. Many models pay for themselves within a year and allow companies to take on additional orders.
Both the implementation process and operation have been further simplified. Many manufacturers offer robotic arms as plug-and-play kits that include actuators, control units, control pads and hubs for cable connections. Cobots can perform onerous tasks with a hugely reduced error rate. The use of robotic arms also enables consistently high-quality production, as they do not make careless mistakes or tire out. The benefits are felt in the production costs, as there are generally fewer rejects. This increases efficiency and opens up new opportunities for innovation and growth, allowing German SMEs to produce goods at internationally competitive prices.
How collaborative robots can optimise your business
Robotic arms help employees and remove the burden of tasks that are hazardous to health, tedious and repetitive. They lift heavy loads, take over quality control, package products, carry out assembly and manufacturing tasks, prepare various surfaces (e.g. painting or grinding) and automate laboratory test series. Advances in gripper technology mean that robots can handle a wide range of objects safely and efficiently, increasing their ability to adapt in various work environments. They also work in hazardous environments that would pose a high risk for people and free up employees to focus on more complex tasks.
It is important that the collaborative robots always work in close cooperation with humans. Unlike industrial robots, they are designed in such a way that they do not require a secure area of activity in which to move. They can typically perform movements similar to the human arm, and depending on the number of axles, they can even exceed the human range of motion. This means that they can move freely around their working environment and complete precise tasks. For example, new image processing technologies such as RGB-D cameras have the ability to interpret visual information in real time and perform complex tasks such as accurately placing components or sorting objects without errors. New sensor technologies are also being deployed to provide support, including particularly sensitive touch sensors or force-torque sensors. These ensure that robotic arms can move and handle objects with increased fine motor sensitivity, widening the scope of tasks that these helpers can undertake and enabling companies to automate additional production or work steps.
Robotic arms carry out tasks based on their programming and can interrupt that programming even at short notice as soon as a person approaches within a certain distance. The continuous advancements in sensor technology mean that robotic arms can accurately perceive their surroundings and detect and respond to human movements in real time. For example, state-of-the-art depth cameras equipped with LIDAR (Light Detection and Ranging) can detect the position of objects and people in the environment of the collaborative robot and track their movements, even if a person slows down or stops moving unexpectedly. This feature is particularly important in dynamic work environments and ensures that employee safety is a top priority.
Decision-making and measurable results
The decision as to whether acquiring a collaborative robot makes financial sense depends on the usage scenario within the business in question and the degree of utilisation. As cobots can affect an entire business, it is advisable to carry out a strategic assessment in advance that goes beyond a simple cost analysis. Key questions include:
Is there a practical application scenario? What does the company hope to achieve? For instance, the goal might be to reduce the number of rejects and improve quality. Of course, every business wants to save money. Once this has been determined, the following question must also be clarified: What tasks can the robot arms perform, and what tasks will the employees then be freed up to do?
It’s also important to consider whether the financial outlay is justified. There are a variety of ways to do this. The manufacturer Universal Robots has some examples for calculating amortisation.
Labour savings: When assessing the benefit of investing in a cobot, the savings in labour or unit costs are calculated — but with the goal of freeing up time rather than creating redundancies. There are two different calculation approaches:
- Annual hours saved x standard cost per hour
- Labour savings per unit (in hours) x standard costs per hour x annual volume
Savings on reworking: Cobots improve process and product quality, which eliminates rework and manual work. The calculation of savings on an hourly basis or as a percentage reduction in total costs is carried out as follows:
- Annual hours saved for rework x standard costs per hour
- Current costs for rework x percentage reduction
Reduction in volume of rejects: Cobots significantly increase quality, meaning that fewer products need to be scrapped and fewer raw materials are wasted. The savings are calculated based on the unit costs or a general increase in quality:
- Percentage of profit improvement x annual production volume x standard unit costs
- Annual units of rejects avoided x unit costs
Increase in production capacity: Cobots take over the monotonous and hazardous tasks, and this creates new capacity with qualified professionals — which in turn improves stability and makes it possible to process additional orders. Consider this: What if a business could ensure optimum utilisation of machines through automation or accept orders it has previously had to decline. The calculation is as follows:
- Unit capacity gains x average sales price per unit x standard margin percentage
If a company or a business has decided to purchase a cobot, this rule generally applies: the acquisition, installation and commissioning costs are roughly double the purchase price of the robot. And if there are still doubts, thinking about this may help: Collaborative robots are highly flexible universal tools and can be easily converted. They can provide continuous support in the right places over many years.
Robotic arms are versatile and can be found nearly everywhere
As a packaging robot
The UF XARM6 model from UFACTORY is an example of how modern cobots can increase efficiency in food packaging as an alternative to conventional industrial robots, packing finished food products from the conveyor belt into boxes. With each movement, the robotic arm grips five packages simultaneously and places them into their boxes with precision. The arm also detects when the box is full and moves on to pack the next empty box. Working alongside the robotic arm, without a barrier or fence, is an employee who collects the filled box. The flexible robotic arm takes over the monotonous and repetitive task of packaging from skilled workers and frees them up to focus on other activities.
As a pick-and-place robot
The next-smallest model, the UF XARM6 Lite, is for gripping and placing products rather than palletising them. In a use case from Laserlux, for instance, it carries out the preparatory work for the large-scale printing of business cards and engraving of logos on plastic cards. Using the UF XARM6 Lite as a pick-and-place robotic arm not only increases production speed for printing, laser work and engraving but also improves the quality of the end products. With fewer rejects and more accurate results, the business is able to lower its prices and accept more orders. This opens up new possibilities for growth and competitiveness in a dynamic market environment.
As a painting aid
Can robots support painters in their work? The Berlin-based startup Conbotics has developed a collaborative robot for precisely this purpose. A professional painter and decorator tried out the painting robot: During the course of the tests he was completely won over by the robot’s performance in terms of speed, precision and material savings. The robot, which autonomously painted the walls using the airless spray process, used 20% less paint than a person and didn’t need to take any breaks. Using the painting robot not only increases efficiency but also facilitates the work of the team by relieving them of strenuous activity (e.g. painting the ceiling) and freeing them up to focus on precision tasks.
Companies can purchase robotic arms such as the models from UFACTORY from distributors such as reichelt elektronik. You can also obtain all the components needed for successful robot design there.
Other trends and technological advancements
Developments with AI and machine learning (ML) will have a lasting impact on HRC. By integrating intelligent algorithms, robotic arms can handle increasingly complex tasks and adapt to changing environments. Enter the humanoid robot. The versatility and flexibility of the HRC systems open up new application areas in various industries, from logistics to healthcare. Mobile manipulators, also known as MoMas, represent an emerging trend that allows robotic arms to move freely in different environments and perform tasks over longer distances, such as harvesting robots in greenhouses. Digital twins give companies the possibility to create virtual models of their physical robots in order to optimise their performance and improve maintenance processes. Finally, intelligent automation and hyperautomation drive the integration of robotics and other automation technologies in order to optimise complex business processes and further increase efficiency.
The future benefit for SMEs
These trends and technological advancements are shaping the future of HRC and they open up exciting opportunities for increasing productivity and competitiveness.
HRC systems can provide a great deal of support in the warehouses of SMEs. MoMa robotic arms driven by AI can learn how to pick and pack various objects in a warehouse at high speed. They use image processing to transport items autonomously within the factory, and they offer AI-controlled interfaces that can reduce the scope of maintenance tasks considerably. Comprehensive analyses of the hyperautomation solutions create the foundation for an intelligently coordinated storage system.
The shortage of a skilled workforce widely discussed in the media also has an enormous impact on businesses which rely on skilled labour. Robotic arms can be used to bridge this gap. Many welding companies, for instance, are experiencing a shortage of welders. Several robot manufacturers have recognised the potential and are providing cobots equipped with special software that turns a universal tool into a productive welding robot. Even putting aside the shortage of skilled workers, the skilled labour sector could still benefit in a variety of ways, as the example with the painting robot clearly shows.
Initial investments pay off in the long run
Thanks to their flexible design, robot arms and cobots are theoretically capable of performing almost any task that can be carried out by humans. In combination with AI-controlled functions in particular, cobots are becoming valuable tools for SMEs and the skilled labour sector.
The main challenges are the initial investment and the integration into existing processes. Companies should therefore carefully consider what tasks can be automated and what strategic objectives they hope to achieve. Thorough planning and selection of the appropriate robotic arm are crucial to success.
Trade fairs such as Motek in Stuttgart (October 2024), SPS in Nuremberg (November 2024) and Hannover Messe (March/April 2025) offered an excellent opportunity to experience the latest robot arms and cobots live. There, companies could not only see the technology in action, but also benefit from expert presentations and best practice examples.
We all have an exciting future ahead of us; one in which HRC systems will play a key role within companies when it comes to increasing competitiveness and efficiency — and perhaps soon will even be painting our living rooms.
Images: Adobe Stock; videos: Ufactory und ConBotics
