When evaluating cost-saving options, many companies consider automation. However, there are prevalent misconceptions about automation, robots, and artificial intelligence that prevent contract packagers from reaping the benefits. The following article will explain the positive impacts of automating with devices like AI palletizing robots in contract manufacturing.
1. Robots Are Too Expensive:
A common misconception among companies considering automation is that robotic systems, such as palletizers, are prohibitively expensive. Many managers worry that the significant upfront capital investment required for traditional automation systems will be difficult to justify without immediate proof of increased efficiency or cost savings. These concerns can deter companies from exploring automation, especially in industries where margins are tight and contracts may be short-term.
However, many automation companies are now offering automation on a subscription basis. Instead of requiring a hefty upfront purchase, subscription or Robots as a Service (RaaS) pricing models help companies automate affordably. This approach eliminates the need for massive capital expenditure, and instead you pay a flat fee per hour of robotic usage on a monthly basis. Tutor Intelligence requires only a one-time deployment fee of $10,000, regardless of the number of systems installed. Tutor’s subscription cost is $14-18 per hour of robot use. The RaaS model is particularly advantageous for small- to medium-sized contract packaging and manufacturing facilities, which often operate on shorter-term contracts.
For these facilities, investing in a traditional palletizer may not make financial sense, as the equipment may not be in use long enough to yield a meaningful return on investment. Instead, a subscription-based automation system, which uses vision technology to be highly adaptable to varying SKUs, is ideal. This flexibility ensures that the technology remains relevant and effective even as product lines or operational needs evolve.
In addition to cost-effectiveness, the adaptability offers peace of mind to operations engineers. They no longer need to worry about technology becoming obsolete or incurring expensive reconfigurations for new products.
Tutor’s solution demonstrates that automation is not just for large-scale enterprises with deep pockets; it’s a practical, scalable option for businesses of all sizes. Click here to check out the pricing model Tutor offers.
2. Robots Can’t Handle Delicate Products:
Unlike line workers, robots do not have the capability or eyesight to understand that the product they are handling is fragile. However, the myth that robots cannot handle delicate products is increasingly untrue. Due to advances in robotic technology, modern robots are equipped with advanced sensors, grippers, and artificial intelligence that allow them to handle delicate products with precision and care.
With the development of soft robotics and force-sensitive grippers, robots can apply just the right amount of pressure to delicate items, minimizing the risk of damage. These innovations have expanded the range of applications for automation, allowing robots to work safely with items that were once considered too fragile for machines. For example, robots can now perform tasks like assembling fragile electronics, picking delicate fruits, or packaging fine glassware—tasks that require a gentle touch.
In fact, the da Vinci Surgical system, which went viral for being used to stitch a grape back together, is increasingly used for cardiac valve repair. If autonomous robots can be trusted to perform delicate surgical precision, they can certainly handle warehouse automation like palletizing boxes that contain glass jars.
Palletizing cobots often feature end effectors that utilize compressed air. This compressed air creates a vacuum, which allows for boxes to be picked up gently with suction. Rather than being limited by the fragility of products, robots today are designed to adapt to a wide variety of handling tasks, including those requiring sensitivity and finesse.
3. Robots Require Constant Maintenance:
Many professionals also feel that investing in automation equipment will result in a maintenance nightmare. In reality, modern robots are designed for high reliability and minimal maintenance. While robots, like any machines, require periodic servicing to ensure optimal performance, they don’t need constant attention. Advances in automation technology have led to robots that are highly durable, with predictive maintenance systems that can detect issues before they become problems.
Most industrial robots, for example, are built to run for thousands of hours with minimal downtime. Many systems are equipped with sensors and diagnostics that monitor performance and alert operators to any necessary maintenance, allowing for proactive fixes rather than constant intervention. With proper installation and regular maintenance intervals, robots can operate smoothly for years without significant disruption.
4. You Need to Be an Expert to Program Robots:
Many people are averse to automation because they fear they do not possess enough robotic or computer science knowledge to get their robots to function correctly. However, modern AI palletizing solutions are designed with incredibly easy-to-use interfaces that line workers can adapt within a matter of minutes. By utilizing plug-and-play commands, employees with absolutely no background in programming can easily work with AI palletizing robots.
5. Robotic Automation Is Dangerous to Work Around:
Many people fear that introducing automation in manufacturing operations also opens a business up to more liability. Concerns around the weight of robotic parts, sensor malfunctions, and the lack of vision in a human sense may make one wary of automation. However, many palletizing systems are equipped with LiDAR (Light Detection and Ranging) sensors, which use laser light to measure distances between the sensor and objects in the environment. Therefore, if a human gets too close to the robotic system, the system pauses its motion until the environment is completely clear from intrusion. LiDAR detection provides over 95% accuracy and reliable performance in all ambient conditions.
Overall, the results of the Case Studies of Robots and Automation as Health/Safety Interventions in Small Manufacturing Enterprises indicated that advanced manufacturing automation, including industrial robots, reduced workplace musculoskeletal risk factors and improved process productivity in most cases.
6. Automated Robots Are Scary:
Many people seem averse to the concepts of “artificial intelligence” and automation. Some fears stem from the portrayals of humanoid robots in movies and TV shows that become highly intelligent and then weaponize their power for evil.
In reality, automated robots are designed to work safely alongside humans and are equipped with numerous safety features to ensure they pose no harm. Collaborative robots, for example, are specifically built to work in shared spaces with people, using sensors and soft materials to prevent accidents.
Robots in industrial settings often work in controlled environments with clear safety protocols in place, such as fencing, emergency stop buttons, and programmed movement restrictions. Plus, robots today are often intuitive and user-friendly, with interfaces that allow easy control and monitoring by operators.
Rather than being “scary,” automated robots are tools that increase efficiency, reduce human error, and improve workplace safety by taking on repetitive or dangerous tasks. When properly integrated, they become valuable team members that enhance productivity and support human workers.
In Conclusion
In conclusion, the misconceptions surrounding automation, robots, and artificial intelligence in contract manufacturing can often prevent businesses from fully realizing the benefits of these technologies. Contrary to popular belief, automation systems such as AI palletizing robots are cost-effective, capable of handling delicate products, require minimal maintenance, and are user-friendly. They are also designed with safety features to ensure they work harmoniously alongside human workers. By adopting modern robotic solutions, companies can increase efficiency, reduce costs, and improve workplace safety. Automation is not just for large enterprises—it’s an accessible, scalable solution for businesses of all sizes, offering a competitive edge in today’s fast-paced manufacturing environment.