The Value of Teaming Humans with Robots and Automation in ...

The Value of Teaming Humans with Robots and Automation in

the Connected FactoryPaul Santi

General Manager – Powertrain Systems Group

FANUC America Corporation

• Achieving the Operational Requirements

• Including the Support Needs

• Awareness of the Environment

• Familiarity with the Connected Factory

• Mindful of the Human Factors

• Traditional and Collaborative Robotic Automation

• Collaborative Robotics Impact on Manufacturing Methodology

• Safety & Safeguarding related to Human & Robot Interaction

So, You’ve Decided to Automate…Now What?

Things to Consider when Automating

Operational – Design – Revenue Impacting

• Part Quality

• Production Schedule

• Talent

• Reliability

• Safety

• Ease of Use

Supporting – Implementation - Investment

• Maintainability

• Personal Training

• Launch Duration

• Spare Parts

• Utilities

• Plant To-Do’s

Awareness of the Environment

• Air

• Floor

• Ceiling / Roof

• External Openings

• Lighting

• Traffic

Familiarity with the Connected Factory

Data

Collection

Cyber

Security

Shared

Learning

Network

Protocol

Plant

IT

Edge

Fog

Cloud Systems able to interact with one another,

analyze data, self configure, and adapt to

changes within the manufacturing process itself

Voltage, Kwh, Running Time,Temperature, Safety

Real-time Data

ANALYTICSPredict component failure

Knowledge Optimize

SMARTMachines & Equipment

CONTEXTUALIZATIONEnergy/Product, OEE, Safety

InformationACTION

More efficient process workflows

Familiarity with the Impact of the Connected Factory

Mindful of the Human Factors

• Safety

• Ergonomics

• Interaction

• HMI Communication

• Emotional

• Human Response

HRI – Human Robot Interaction

Not Just a Machine

• “On the one hand, these robots are just another modern machine to enter the factory. However, new research shows that people don’t treat them that way; rather, they treat them as living things.”

Commands: Human Self Doubt

• “Companies should be aware of the persuasive power of directions when coming from a social robot, and create policies and procedures for identifying situations where there is a human-robot disagreement and what to do when there is.”

Source: WSJ June 02, 2015

HRI – Human Robot Interaction

Empathy toward Robots: Protection from Damage / Harm.

• “People feel bad when bad things happen to robots.”

• “…Companies might want to separate robots that do collaborative tasks (thus building rapport) from those that do dangerous ones (and be at risk). That would minimize opportunities for workers to directly observe robots being mangled or disassembled.”

Source: WSJ June 02, 2015

What Does Collaborative Mean to You?

• Cohabitating?

• Nearby?

• Helping each other?

• Working together?

Assisting

Enhancing

• Home Service

• Humanoid

• Driverless Car

• Telepresence

• Exoskeleton

• Terminator

• Optimus Prime

• AGV / Mobile Platform

• Same as any other robot?

Your View of “Collaborative Robotics”?

Both of these are ‘Collaborative Ready’

What Features Do You Think Are Built-In?

• Safe? With NO additional Safeguarding? ………… Unlikely.

• Simple & Easy to Program? ……………………….. Depends.

• Direct Replacement for an Operator? ……………. Rarely.

• Industry accepted (they must be, right?) …………. Please Confirm!

• No engineering needed? …………………………… Yeah, Right!

• Accepted by co-workers? ………………………….. Can Be!

Do you know the Truth vs. Myth?

Why is Your Company Going Collaborative?

• Everyone else is doing it.

• My boss says we have to.

• Ergonomic lost-time issues.

• No floor space for ‘traditional’ robot.

• Easier to deploy than an operator?

• No time to engineer a new system.

Ideally:

The application is optimized by combining the values

of Robotic Automation with Human Skill & Intelligence.

Education: Become familiar with the types of Collaborative Operation

Proper Application Requires Knowledge

Analyze: Which is the best type for your application?

5.10.2Safety-rated monitored

stop

5.10.3Hand

Guiding

Collaborative Operation Types

5.10.4Speed and separation monitoring

Analyze: Or is one of these better for your application?

5.10.5Power & Force Limited

Collaborative Operation Types

Education: Become Familiar with industry accepted Guidance.

With Knowledge Comes Ability

ISO/TS15066:2016

Source: RIA Editorial POSTED 07/05/2016

Robots, Jobs and Productivity in the Manufacturing Industry

As robot shipments increase, so has nonfarm employment.

More Robots = More Employment

Robot shipments are also linked with the

growth in manufacturing labor productivity.

Source: RIA Editorial POSTED 07/05/2016

Robots, Jobs and Productivity in the Manufacturing Industry

More Robots = More Productive Labor Force

Source: RIA

More Robots … Year over Year

• Ordered Units Increased.

• Ordered $$$ Increased…but at lower rate.

“American Industrial Automation Growth to Stay Strong”, says RIA.

33

25

24

22

22

21

21

20

18

18

16

14

13

9 9 9

8 8 8

7 7 7

6

3

0 0

LABOR-COST SAVINGS FROM ADOPTION OF ADVANCED INDUSTRIAL ROBOTS (% 2025 PROJECTED)

Total Cost of Robotic Automation is Decreasing

Source: Boston Consulting Group (via The Fiscal Times)

Why This Matters to Collaborative Robotics?

• Applications are expanding.

• Robot Costs are Declining while Performance (Speed, Capability) is Expanding = More Opportunities.

• Robots are increasingly replacing fixed automation.

• Robots are replacing many manual tasks.

• Technology has reached point where research has resulted in capability that is now commercially available.

More Collaborative is on the way.

Thinking of Using a Force and Power Limited Robot?

Things to Consider

Risk Assessment is Still Needed

• ANSI/RIA R15.06-2012

• Functional Safety

• TS15066 Guidance• Forces & Pressures

• Safety Rated Axis Limits

Sharp Edges

Trip Hazards

Pinch Points

Consider Hazards Beyond the Robot

Process

Forces and Pressures – ISO/TS 15066:2016

Body Region Specific Body Area

Quasi-Static Contact Transient Contact

Maximum

Allowable

Pressure

[N/cm2 ]

Maximum

Allowable

Force

[N]

Maximum

Allowable

Pressure

Multiplier

Maximum

Allowable

Force

Multiplier

Skull and forehead

Middle of forehead 130

130

N/A

N/ATemple 110 N/A

Face Masticatory muscle 110 65 N/A N/A

Neck Neck muscle 140150

22

Seventh neck muscle 210 2

Back and shoulders

Shoulder joint 160210

2 2

Fifth lumbar vertebra 210 2 2

Chest Sternum 120140

22

Pectoral muscle 170 2

Abdomen Abdominal muscle 140 110 2 2

Pelvis Pelvic bone 210 180 2 2

Upper arms and elbow joints

Deltoid muscle 190

150

2

2Humerus 220 2

Lower arms and wrist joints

Radial bone 190

160

2

2Forearm muscle 180 2

Arm nerve 180 2

Hands and fingers

Forefinger pad D 300

140

2

2

Forefinger pad ND 270 2

Forefinger end joint D 280 2

Forefinger end joint ND 220 2

Thenar eminence 200 2

Palm D 260 2

Palm ND 260 2

Back of the hand D 200 2

Back of the hand ND 190 2

Thighs and knees

Thigh muscle 250220

22

Kneecap 220 2

Lower legs Middle of shin 220130

22

Calf muscle 210 2

You don’t need to be a Medical

Doctor but need to consider contact.

• Forces & Pressures

Features required by the application still need to be used with a collaborative application.

Force Sensing Vision High Accuracy

Collaborative Operation Safety was Addressed

What Next?It’s All About the Process…..

• Still need to achieve Production and Quality levels.

• Still Need to Control the Process

• Communicate with External Equipment

New Applications but Same Challenges

• Integrate into Larger Manufacturing Systems

Technology Acceptance by “The Next Generation”

• The rules for robotics in manufacturing have taken 30+ years to be understood; people are separated from robots.

• With new technology, the rules have been rewritten.

• Clear indications of robots using “new rules” is needed especially with Power and Force limited robots.

Step Into Tomorrow – Today!

• Collaborative Operation Capabilities are opening new opportunities for Robotics.

• Advances in Machine Vision, Machine

Intelligence, Smart Devices, and the

Connected Enterprise will further

enable the opportunities.

It’s best to be prepared

What Matters Today Will Matter Tomorrow

• Safety

• Productivity

• Interoperability

• Capability

• Durability

• Flexibility

• Reliability

Contact

Paul SantiGeneral Manager – Powertrain Systems Group

FANUC America Corporation

3900 W. Hamlin Rd.

Rochester Hills, Michigan 48309

U.S.A.

Telephone: 248-377-7383

Email: [email protected]

www.fanucamerica.com

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