The construction industry is probably one of the last holdouts when it comes to adding automation and robotics to its assembly lines. In many cases it’s not the initial cost of either but rather how should they be integrated into the existing line, what are the operating costs and where to find enough space in the older factories for automated wall panels and trusses stations.
Most new offsite wall and truss manufacturers as well as new modular and manufactured factories are being designed with both automation and robotics. Retrofitting older factories are still being put on the back burner for now.
When looking at designing a new offsite factory, automation and robotics will be an important part of the plan. While automation and robotics sound like they do similar jobs, there are big differences in how and what each does.
At its most basic, the difference here is that an automaton carries out predetermined actions based on specific instructions. Robots can operate on their own and are programmable, which gives them a level of versatility. Automatons can only perform a limited number of functions based on very precise inputs.
Another question always asked by owners and investors is “how much will it cost?” However, “how much will it cost not to automate?” is a better question today with the rising cost and shortage of labor.
Robotics can cost from $50,000 to $80,000 each. Once application-specific peripherals are added, the robot system costs anywhere from $100,000 to $150,000 each. Generally speaking, the cost of building automation and robotic systems is anywhere between $3.75 and $10.50 per square foot for a new factory and almost double that for refitting an older production line.
Here are some Pros and Cons to consider when looking to add Robotics to either a new or older offsite factory production line.
Pro: Improved Productivity
A recent industry study reports that 23% of unplanned downtime in the manufacturing industry comes down to human error. There are many factors that contribute to this staggering number, particularly the lack of training for machinery operators. The programmability of industrial robotics means they can be installed to perform a huge range of tasks and can start on day one after installation, where an operator would need time to train.
Pro: Improved Quality
Accuracy and repeatability are integral to quality, and industrial robots are designed to deliver both. With the high degree of accuracy that robots deliver in assembly and manufacturing, there are fewer mistakes and fewer wasted products.
Pro: Easily Integrate with Production Lines
Integration is made even easier when conveyors and robots are run on the same controller or programmed together. This ensures that the product is in the proper position at the exact right time to interface with the robot.
Con: High initial investment
The obvious downside to implementing robotics and automation in manufacturing is the high initial investment. Robotics are highly customizable, but that means that the price tag attached to building and programming a system can be more than a company is comfortable investing for one portion of its production line.
Con: Expertise can be scarce
Related to the high initial investment, expertise in robotics manufacturing and maintenance can be scarce. While the industry is quickly growing, it is still a niche area, and the knowledge to create or adjust programming can be hard to find outside of the OEM of the robotic system.
The lack of expertise also means that staff will need to be trained by the OEM on proper maintenance or operation of the robotic system. This may add additional time and cost to the initial implementation of the system as well.
Con: Technology Limitations
Finally, there are still some limitations to existing robotics technology when it comes to manufacturing processes. As of today, robots are ideal for repetitive tasks, but some production processes require a higher level of complexity than robots can accomplish.
Even with the Cons mentioned above, the cost needed to install robots and the skilled technicians needed to program them, it is becoming easier to justify those costs.
Some day the offsite industry will simply order standardized-function robots and that day isn’t far off.
Gary Fleisher is the Editor in Chief of Modular Home Source and Offsite Builder.
Gary Fleisher, Editor in Chief of Offsite Construction Magazine
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