How are robots used for quality control in manufacturing?

Robotic systems in manufacturing have taken on the pivotal role of ensuring product quality through various sophisticated applications. One of the most common uses is through automated inspection systems, where robots equipped with high-resolution cameras and sensors conduct meticulous inspections of products as they move along the production line. For instance, in the automotive industry, robots are used to inspect welds and paint finishes, which require an extraordinary level of detail, surpassing what is typically possible by human inspectors.

Another practical application is in the electronics sector, where robots perform precision checks on circuit boards. Equipped with advanced vision systems, they can quickly identify defects such as misalignments or missing components, tasks that are not only tedious but also prone to human error.

Furthermore, in the pharmaceutical industry, robots handle and inspect vials and syringes, ensuring that they are correctly sealed and contain the correct dosage, a crucial factor for patient safety. This robotic assistance provides consistency and precision paramount in industries where the margin for error is virtually nonexistent.

By integrating with data analysis tools, these robotic systems can also help in predictive maintenance. They can detect subtle changes in equipment function or product quality, alerting human operators to potential issues before they become significant problems.

The use of robotics in quality control processes represents a significant shift towards more efficient, accurate, and reliable manufacturing practices, supporting industries to deliver flawless products to the market.

What types of robots are used for quality control?

The manufacturing sector employs a variety of robots for quality control tasks, each designed to perform specific functions with high efficiency. Articulated robots, with their rotating joints, are among the most versatile. They are commonly used for tasks requiring a range of motion, such as picking and placing components or reaching into tight spaces to conduct inspections.

SCARA robots

SCARA robots, known for their high speed and precision, are ideal for smaller tasks, such as those in the electronics industry, where they handle and inspect small, delicate parts. Their rigid structure and precise movements make them particularly useful for repetitive tasks that require exact precision.

Delta robots

Delta robots are frequently used in quality control for their exceptional speed and accuracy. Their design allows them to move quickly and precisely in three dimensions, making them well-suited for packaging inspections in industries like food and beverage, where manufacturers can pair them with vision systems to sort, orient, and inspect products at high speeds.

Collaborative robots

Collaborative robots, or cobots, are designed to work alongside human operators. These robots are equipped with sensors that allow them to work around people while significantly reducing the risks associated with working around robots. Cobots are becoming increasingly popular for quality control tasks as they can be easily integrated into existing workflows and require minimal changes to the production line.

Mobile robots

Mobile robots are gaining traction in warehouses and manufacturing floors. They can transport goods from one location to another and are increasingly being equipped with inspection capabilities to check the quality of products as they move through the supply chain.

Each type of robot brings its unique strengths to the quality control process, and the choice of robot often depends on the specific requirements of the task, such as speed, precision, reach, and the ability to work in collaboration with human employees.

What are the advantages?

Robotic systems in quality control offer advantages that enhance the manufacturing process.

Consistency and precision

Robots are engineered to perform tasks with a high degree of accuracy and can maintain this precision over long periods without fatigue, leading to consistent product quality. This is incredibly impactful when performing quality control on products where the fine details matter, such as aerospace weld inspection.

Increased production speed

Robots can operate at a pace that far exceeds human capabilities, which can significantly accelerate production lines and increase throughput. Pairing a delta robot with a vision system for inspecting and sorting food products moving down a production line will be substantially faster than the manual version of this process.

Reduced costs over time

While the initial investment in robotic systems can be substantial, they can lead to cost savings in the long run through improved efficiency, less waste, and lower error rates. Manufacturers often plot out the gains due to increased production quality, throughput, and reduced rework/waste costs to determine the value of a quality control automation system.

Enhanced safety

Robots can take over dangerous or unhealthy tasks, reducing the risk of accidents and exposure to hazardous conditions for human workers. This risk is pronounced when production occurs in conditions unsuitable for humans, such as extreme temperatures or cleanroom environments required for semiconductor manufacturing. Increased safety impacts employee morale and reduces the risk of fines and litigation from regulatory agencies.

Data collection and analysis

Most modern robot systems can collect data on product quality and other metrics. This data can provide insights that can be used to optimize the manufacturing process further and indicate potential issues early. Thinking about quality control as more than another step in the production process creates a distributed system of real-time testing, analysis, and adjustments. This capability makes them an even more valuable addition to manufacturers’ operations.

Flexibility

Many robotic systems can be reprogrammed and tooled to perform different tasks, allowing for greater flexibility in production and the ability to adapt to changes in product design or demand.

What are the limitations?

Despite the numerous benefits, there are limitations to the use of robotics in quality control that manufacturers must consider.

Initial investment and upkeep costs

The upfront costs for robotic systems can be significant, including the expenses for the robots themselves, installation, programming, and integration into existing systems. Additionally, ongoing maintenance and updates can add to the overall cost.

Technical complexity

Implementing robotic systems requires specialized knowledge and skills. Manufacturers may face challenges finding qualified personnel to operate and maintain these advanced machines. 

Additionally, incorporating robots into an established production line can sometimes be challenging, especially in older facilities that were not originally designed with automation in mind.

Limited adaptability

While robots excel at repetitive tasks, they may lack the adaptability and problem-solving abilities of human workers. Complex or unexpected situations may still require human intervention. It is important to understand the limits of a proposed automation system in the context of your specific application.

Understanding these limitations is crucial for manufacturers to realistically assess the role of robotics in their quality control processes and to develop strategies to mitigate these challenges.

How big is the market?

The market for robotics in quality control within the manufacturing industry is witnessing significant growth. Recent estimates suggest that the global market for industrial robots is expected to see a compound annual growth rate (CAGR) of 5.66% between 2022 and 2027.

The surge in demand is driven by various factors, including the increasing emphasis on precision and efficiency, the need for operational cost reduction, and the rise in labor costs. Additionally, technological advancements are making robots more accessible and cost-effective for a broader range of applications.

A few industries are ahead of the curve for automated quality control. The automotive industry remains on the leading edge of industrial robots for quality control. The pharmaceutical industry is also rapidly adopting robotic systems to ensure compliance with stringent quality and safety standards while reducing costs.

As the technology continues to advance, it is expected that more industries will embrace robotics for quality control, further expanding the market. The integration of artificial intelligence and machine learning is poised to create even smarter robotic systems capable of more complex tasks and decision-making, opening up new market segments and opportunities for growth.

For manufacturers and industry decision-makers, staying informed about the robotics market and its trajectory is essential for strategic planning and maintaining a competitive edge in quality control practices.

What’s next?

Read our next article on how quality control robots are being used in the food and beverage industry. [coming soon]

You may be ready to take the next step toward improving your quality control processes, but where do you start?

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