Why Automation and Robotics Are Gaining Traction in Small and Midsize Manufacturing

Automation and robotics have proven instrumental in delivering products with increased efficiency and safety across a range of industries. Yet, until recently, many small and midsize manufacturers had not fully leveraged these technologies to the same extent as larger enterprises. This trend is beginning to change with the advent of collaborative robots—or cobots—and modern vision systems.

The Challenge of Justifying Automation and Robotic Investments

For years, automation and robotics have primarily been utilized for high-volume, relatively routine operations, such as assembly lines in automotive or electronics manufacturing. These production lines operate continuously for extended periods and are situated in highly controlled and predictable environments. The highly favorable ratio of the total value of goods produced to the cost of automation there makes robotic investments particularly cost-effective.

However, investments in robotics have historically been harder for small and midsize manufacturers to justify, especially for those involved in producing lower volume, complex products. These items, though often intricately designed and critical in nature, present significant hurdles for automation due to their complex assembly and production processes. The challenge is even more pronounced among contract manufacturers and supply chain vendors serving top-tier companies.

As production volume decreases, the ratio of production output to automation cost drops significantly, making the savings from automation versus manual labor less pronounced. In essence, the costs associated with automation can become prohibitively high compared to manual operations.

Another consideration is that many traditional automated operations were developed from scratch, both in product design and factory layout. Such custom setups are rare in small and midsize manufacturing, where facilities often need to accommodate multiple products and processes. Consequently, automation within these environments has typically been limited to basic tasks like pick-and-place.

The cumulative result of these factors is that automation remains underutilized. Of course, islands of automation exist, performing repetitive tasks to augment predominantly labor-intensive processes. This might involve three-axis machines with articulated end-of-arm tooling or conveyor systems designed to assist human operators. However, a fully automated, interconnected assembly line remains an exception rather than the norm.

Expanding Automation via Cobots and Modern Vision Systems

Today, cobots are opening new avenues for automating the lower volume, higher variability tasks commonly found in small and midsize manufacturing operations. Several key distinctions set cobots apart from traditional robots.

• First, cobots are designed to work alongside humans, making them inherently safer. They are engineered to be acutely aware of velocity and force, minimizing the risk of injury to employees working in close proximity.
• Second, cobots exhibit smooth, contoured motions that allow them greater flexibility to navigate around objects, enhancing their adaptability to changing circumstances.
• Third, and critically, cobots are easier to program. They are usually configured with pendants—essentially joysticks—that enable operators to guide the collaborative robot through processes and memorize procedures. As a result, training can be conducted by technicians rather than requiring highly skilled programmers.

In addition to cobots, modern automation cells frequently incorporate advanced vision systems that collaborate with robots to ensure tasks are executed correctly. The primary improvement here lies in usability.

Older vision systems demanded considerable technical expertise for proper setup—not just in image or pattern recognition but also in the lighting and presentation aspects necessary for reliable visual inspections. In contrast, today’s vision systems, augmented by powerful cloud-based learning and analysis tools, are easier to train and more forgiving of imperfect lighting and placement conditions.

Shifting the Automation and Robotics Value Equation

There is a value equation for automation that includes two main positive factors: labor savings and faster, more reliable operations. On the negative side are the costs of robotic equipment, end-of-arm tooling, safety measures, programming, and ongoing maintenance and changeovers.

Cobots and modern vision systems positively impact both sides of this equation. Their flexibility and ease-of-use create new automation opportunities in small and midsize manufacturing sectors that were previously too low-volume for automation. Simultaneously, they are simpler to set up, require less fencing and guarding, and do not necessitate expensive technicians for programming, setup and maintenance.

Crucially, cobots and vision systems can be integrated into existing facilities and product designs. This capability—combined with reduced costs, higher ease of use, support for more complex tasks, and the ability to operate alongside human workers—is driving the next wave of automation in the small and midsize manufacturing sectors.

By embracing these advancements, small and midsize manufacturers can enhance their operational efficiency, reduce labor costs, and achieve greater consistency and reliability in their production processes, ultimately gaining a competitive edge in an increasingly automated world.