Cutting Through the Complexity: Getting Real on Incorporating Robotics into Your Operation & Proving ROI

Companies often find robotics intimidating, and employees fear that these machines will take their jobs. The truth is robots are more accessible and easier to implement than many realize. They aim to elevate human jobs, not replace them. Robots can take over specialized, repetitive tasks—often called the “3Ds,” or the dirty, dull and dangerous jobs—that humans perform on the factory floor. By doing so, robots create a safer and more enjoyable work environment for employees.

For example, an automotive manufacturer decided to use mobile robots as part of a pilot program to detect leaks in their compressed air system. During that pilot phase, the robot detected more than 60 air leaks, which helped the company save an estimated $65,000-$85,000 per year. Taking the repetitive, mundane inspection tasks away from the human workers freed them up to do more important tasks.

However, before diving into robotics, companies must understand the goals for these innovations. Defining the robot’s purpose and what it’s meant to accomplish is essential. Without clear objectives, measuring the success of the implementation becomes difficult. In tandem, organizations must outline the critical elements needed to make any robotic implementation successful—including the technical components involved, programming needs, maintenance requirements and safety laws.

Let’s explore those elements and discuss how to measure the ROI of robotic investments.

Set the Stage for Success

When people think of robots, they often envision droids from science fiction that march in and aggressively solve problems. This perception can make robotics feel intimidating. However, drawing parallels to familiar technologies when introducing robots into operations can ease the transition. For example, if companies already use sensor technology or embedded systems, they’ll have a baseline understanding of some of the technology that powers robots.

Although robots seem complex, you can often prep a robot right off the trailer in an hour. Most Graphical User Interfaces (GUIs) are easy to use and could be programmed by someone familiar with a handheld game system. Programming is crucial since robots can only perform tasks they’re programmed to do. Therefore, companies must understand the software components powering the robot before getting started. Additionally, there are often accessories and add-ons that don’t come as part of the out-of-the-box solution. It’s important to clarify the value of these extras and whether they’re needed for the implementation.

Environmental factors also impact the robot’s performance. For example, cameras that enable robots to “see” can be affected by ambient light or dimly lit areas, while dust and particles in industrial settings can damage mechanical parts or reduce accuracy. Setting up the robot’s environment for success is vital.

Another critical consideration during the planning phase is understanding safety laws. The devices that interpret the robot’s environment must comply with safety regulations, including the use of pressure mats, sensors and safety gates.

Finally, when implementing robotics for the first time, it’s beneficial to assign a singular, specialized task to the robot instead of trying to tackle multiple jobs. This approach ensures a clear goal for the robot and simplifies ROI calculations and smoother technology adoption.

Getting the Robot Started on Tackling Tasks

Due to the flexibility of robotic technology, companies may feel overwhelmed by all the possible tasks robots could perform. To prevent this, focus on tasks that provide quick returns and build confidence. Over time, your organization can evolve toward more complex tasks.

For example, instead of trying to solve the largest challenge, focus on simpler tasks like material handling. These areas offer more immediate ROI and can help your organization specialize in one solution set. For instance, it may be more effective to start with palletizing or welding and deburring in a specific vertical. As the robot becomes proficient in these tasks, it can branch out into other areas like assembly.

Maintenance Matters

Like all machinery, robots require ongoing maintenance to optimize performance, including preventive maintenance schedules. Robots, like most moving machinery, are prone to wear-and-tear. Many components, such as bearings, are designed to fail to prevent more expensive parts from wearing out prematurely. Preventive maintenance schedules are essential to maximize the value of your investment.

For example, removing bearings, replacing them with new ones, checking motor torque limits and ensuring the gearboxes remain in good working order are all preventative maintenance tasks that should be incorporated to help boost uptime. Another critical component is the rubber suction cups in the robot’s tooling, which break down over time and need replacing to maintain performance.

Understanding the shelf life of various components and staying on a maintenance schedule will help companies accurately calculate the costs associated with robot upkeep and determine the ROI of robotics investments.

Measuring the ROI of Robotics Implementations

Before calculating ROI for robotics, companies must consider several factors, which we’ve broken down into four steps:

Remember your goals. Revisit the problem or scenario the robot was meant to improve. How much did the problem cost? What specific goals did the robot aim to achieve? What parameters did you set to measure its impact?
Address workforce shortages. Robots can play a vital role in helping businesses address ongoing skilled labor shortages. Taking on mundane, dangerous or repetitive tasks allows human workers to focus on more critical and engaging activities. Not only can this help enhance overall productivity and job satisfaction, it can also positively impact worker safety. Eliminating repetitive tasks that pose ergonomic challenges, or dangerous tasks like temperature reading or voltage testing, can help reduce workplace injuries and risks.
Uncover unexpected returns. Sometimes robots solve problems beyond their initial, intended purpose, generating cost and efficiency savings. For example, in the auto manufacturer case study referenced above, the robot was also able to identify electrical overheating issues in their equipment. The company estimated that this could have cost tens of thousands of dollars in unplanned downtime. Instead, maintenance teams were able to repair the equipment during scheduled downtime. And since the robot was able to handle the more mundane inspection tasks, human workers were freed up to focus on more critical issues. Consider these unanticipated returns in your ROI analysis.
Confirm if there are ways to cover your investment. Before making robotics investments, review tax incentives and government programs. For instance, some states offer investment tax credits for smart manufacturing, which can help make the initial cost more attractive.

After considering these factors, companies can decide whether to implement dedicated machinery, robots or a multi-tiered approach. Though the simplest solution often wins, robots generally offer the most flexibility. If you’re thinking about implementing robotics for the first time, working with a partner who understands the landscape, best practices and ROI opportunities can help ensure success.