PACKAGING INTELLIGENCE BRIEF. Trends in Robotics. Market Assessment APRIL 2014

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1 PACKAGING INTELLIGENCE BRIEF Trends in Robotics Market Assessment APRIL 2014

2 11911 Freedom Drive Suite 600 Reston, VA Tel: Toll-Free: ASK.PMMI This report is confidential and subject to change without notice. This report contains information protected by copyright. Copyright 2014 PMMI, The Association for Packaging and Processing Technologies, Inc. All rights reserved. The information contained herein shall not be distributed or shared by the recipient. No part of this document may be reproduced without the express written permission of PMMI.

3 Trends in Robotics Market Assessment OVERVIEW The 2014 Trends in Robotics report summarizes interviews with 100 product manufacturers, OEMs, integrators, industry suppliers and experts. They provide insight into the drivers of increased integration of robots on the plant floor for packaging and processing and how the changing dynamics of global competition are influencing the adoption of robots and the design of future robotic technology. Key Trends The key trends that are expected to strengthen the business case for robot adoption, expand manufacturers use of the technology and influence design during the next 5 years include: Vision sensors that increase the precision and handling of objects - distinguishing the differences in size, shape and color End-of-arm-tooling (EOAT) or end effector advances Integrated robot controls Improved sanitary designs to allow direct contact with food products Faster operating speeds and increased lifting capabilities Safety autonomy for robots with spatial awareness operating in collaborative work cells with humans Decreasing costs that make robotics more affordable ROBOTS SEE MORE CLEARLY The inclusion of vision sensor technology gives the robot eyes for capturing and identifying images and dimensions of the objects to be picked up. It has led to advances in EOAT design for nimble handling by claws, grippers, pinchers, magnets, vacuum and suction devices. Equipping robots with vision sensors capable of computing the depth and orientation of the object, adjusting their focus as lighting conditions vary, has greatly improved robots accuracy in identifying randomly sorted objects and placing them. Typically the controller and camera make up the hardware elements of a vision system, guided by software in the controller. About half the robots currently used by consumer packaged goods manufacturers have vision sensors, a percentage that is expected to grow significantly in the next 5 years.

4 P A C K A G I N G I N T E L L I G E N C E B R I E F Vision Sensor Tech in Pharma Pharmaceutical manufacturers are applying the vision sensor technology to help with serialization. During the past decade, the pharmaceutical industry has been working to implement item-level serialization and e- Pedigree data transfer for end-to-end tracking and tracing capabilities. Vision sensor technology makes it possible for pharma manufacturers to print a unique serial number on the drug package, link that number to the secondary packaging carton, and then track individual cartons loaded on the pallet through their journey to the store shelf. Pharma manufacturers are optimistic that vision sensors will enable verification of serialization numbers before a product leaves the plant. A major advancement in vision sensors is color imaging which allows more accurate differentiation between objects of the exact same shape and size, such as bottle caps or packages that use color coding to designate the type or strength of the product. Some pharmaceutical manufacturers are already starting to make use of color vision sensors for product inspection. INTEGRATED CONTROLLERS Controllers and the software are the robot s brain. As deployment of robots has expanded at the front of the processing line to the end of the packaging line, robot manufacturers and integrators have begun moving away from proprietary controllers and toward PLCbased controllers. The primary benefit of PLC-based controllers for manufacturers is that machine engineers do not need to learn a proprietary programming language; most machine engineers are already familiar with PLC programming. Tertiary benefits of PLC-based controllers include common programming controls, software interfaces, program backup and restoration methods, as well as program documentation. As a result, PLC-based controllers provide an open architecture that makes it easier for manufacturers to interface other components in the packaging line, such as human machine interfaces (HMI) and proprietary components. The payoff for manufacturers is as robots become more software driven, programming can be accomplished by internal engineers. Robotic Engineering Expertise Shortage Despite the trend toward PLC-based controllers, OEMs and robotic integrators are feeling a shortage of robotic engineers with the skills and knowledge to operate PLCbased controllers on robots. OEMs also have concerns about the shortage of workers with engineering expertise to design controllers and end effectors for robots. One solution to the shortage of engineers with the skill set to design and program PLC controllers is for OEMs to work more closely with integrators to make robotic controllers more compatible with other applications and user friendly. The latter can lessen the learning curve for engineers to program robotic controllers. 2 M A R K E T A S S E S S M E N T

5 SANITARY DESIGNS Food processing manufacturers desire to implement robots on their lines is compelling robot manufacturers to design robots with smoother surfaces without angles or corners where bacteria can be trapped and tighter seals that lock out contaminants for washdown. Also fueling this trend is the Food and Drug Administration s (FDA) approval of washdown robots and grippers for use in direct food contact. The smooth, protective surfaces of washdown robots prevent the build-up of food particles that can lead to bacterial contamination or rust build-up. The surfaces can also be washed with bacteria killing chemicals to make the surface and EOAT aseptically clean. Some food processors are considering robot use for tasks to be performed in sanitary conditions, in part to comply with the Food Safety Modernization Act (FSMA). The FSMA holds manufacturers accountable for adhering to the Preventive Controls rules which dictate how high risk food products will be controlled. Robots are a way for food processors to eliminate contamination from human contact with food products on the processing and primary packaging lines in compliance with FSMA guidelines. Despite advances, robots remain under-utilized on the processing line according to several robot manufacturers and OEMs. More than half (59%) of the manufacturing locations interviewed neither use robots on their processing lines nor plan to in the next 5 years. Of the companies currently using robots on the processing line, more than half expect to increase their use in the coming years. MORE SAVINGS, BETTER SAFETY In today s economy, manufacturers need to run leaner and more efficiently to keep pace with the competition. Robots can provide an efficiency advantage over human workers because they can run 24/7 without a break, remain accurate and consistent, and lift heavy loads, without risk of physical injury or the down time associated with workplace injuries. The payoff for manufacturers is cost savings, as robots can perform repetitive, manual tasks that are not economically viable for higher wage, skilled workers. Additionally, the small footprint of most robots allows them to be deployed in areas with limited floor space to perform tasks that pose high health and safety risks for human workers. One significant safety challenges facing manufacturers in their use of robots is making certain they do not cause work place injuries as humans come into contact with them. Advances in controller software make it possible to dictate the robot s range of motion T R E N D S I N R O B O T I C S 3

6 P A C K A G I N G I N T E L L I G E N C E B R I E F and operating speed to allow a human worker to perform tasks alongside it without risk of being struck by the rotating arm. It is possible to employ the technology alongside human workers to increase productivity, each performing the task for which they are best suited. There are times a robot can complement a worker, not replace the workforce, says a Packaging Engineer for a medical device manufacturer. as the cost advantages from reduced labor and worker liability costs. By approaching the design and implementation of robots from an end user s perspective OEMs can deliver the features and functionality end users expect at the price point they need. OEMs that do so will enjoy greater customer loyalty, a stronger brand and increased sales. POSITIONING FOR THE FUTURE As with any technology, costs come down as it becomes more widespread. While the growing installed base of robots has made robotics technology more affordable, packaged goods manufacturers expect subsequent generations of the technology to deliver even greater productivity. Robots of the future will deliver higher performance through increased functionality and flexibility so manufacturers can boost their global competitiveness. Some of the ways OEMs can deliver manufacturers wish lists and expectations include: Seamless integration of controllers Vision systems and HMI s integrated with the PLC to allow for simpler and faster programming changes Smaller footprint End effector innovation and EOAT that can be changed faster to reduce downtime End users are looking for functionality as well 4 M A R K E T A S S E S S M E N T

7 PMMI s BUSINESS INTELLIGENCE COMMITTEE Alan Shuhaibar, Chairman, Business Intelligence Committee, BellatRx Inc. Roger Altendorf Bradley Budde Eric Cummings Julie Deehr John Eklund Ginny Fox Wayne Goldberg Lisa Hunt Paul Johnson Dustin Lee Ed McGovern Brian Miller Steve Mulder Neal Nordling Pat O Connor Marc Ostertag Gary Saunders Dan Sheba Pete Shumway Randy Spahr Enfield Technologies Pillar Technologies, An ITW Company Ross Controls SMC Corporation of America Pro Mach, Inc. 3M Econocorp, Inc. Plexpack Corp. Weber Packaging Solutions, Inc. Morrison Container Hadling Solutions Piab Inc. JLS Automation Aagard Multifeeder Technology, Inc. Columbia Machine, Inc. B&R Industrial Automation Corp. Magnum Systems Cone Drive Matthews Marking Systems ARPAC

8 About PMMI PMMI is a trade association representing more than 650 packaging and processing supply chain companies that provide a full range of packaging and processing machinery, materials, components and containers. PMMI actively brings buyers and sellers together through its various programs including: The PACK EXPO family of trade shows, packexpo.com, PMT Magazine, PACK EXPO Show Daily, networking events, educational programs and more. PACK EXPO PMMI organizes the PACK EXPO trade shows: PACK EXPO International, PACK EXPO Las Vegas and EXPO PACK México, connecting participants in the packaging and processing supply chain with their customers around the world. Coming Up: EXPO PACK México 2013 at Centro Banamex, Mexico City, June 17-20, 2014; PACK EXPO International at McCormick Place, Chicago, November 2-5, 2014; PACK EXPO East at Pennsylvania Convention Center, Philadelphia, February 16-18, Learn more about the Robotics Industry! PMMI s Trends in Robotics Market Assessment Study can be purchased for $3,500 at or by contacting Paula Feldman, Director, Business Intelligence, at or pfeldman@pmmi.org.