Over 1,500 manufacturers worldwide responded to Rockwell Automation’s 9th Annual State of Smart Manufacturing Report to provide insights into the industry’s current disruptors, including emerging technologies and their potential to alleviate the biggest challenges facing manufacturers today. Phil Hadfield, UK Managing Director at Rockwell Automation, explains.
Today’s labour shortage and skills gap intensify the difficulty of attracting, managing and retaining skilled workers. Attracting employees with the desirable skill sets is the top internal obstacle to an organisation’s growth, and a shortage of qualified workers is the fourth highest external obstacle – this challenge was prominent in 2023 as well.
A new era for workforce empowerment
The realm of industrial automation is undergoing a transformative shift, heralding a new era of workforce empowerment. The State of Smart Manufacturing report revealed that internal and external obstacles are prominent across the manufacturing industry and are especially challenging as demand continues to grow.
For two years in a row, manufacturers have cited a lack of a skilled workforce as the top reason they will struggle to outpace their competition. To solve these challenges, investment in innovative manufacturing technology has increased 30 per cent year-over-year, from 23 per cent of operating budget in 2023 to 30 per cent in 2024.
According to the report, the top method manufacturers are specifically addressing the industry’s labour shortage and skills gap is by increasing automation. Smart manufacturing technologies, such as industrial control systems, asset performance management solutions, manufacturing execution systems (MES), and production logistics solutions like autonomous mobile robots (AMRs), serve as effective tools to combat the labour shortage. Among these technologies, AMRs rank within the top three investments planned by manufacturers in the coming 12 months.
Advanced technologies such as collaborative robots, AMRs, automated guided vehicles (AGVs), and wearables are not just revolutionising traditional manufacturing paradigms, but also opening up unprecedented avenues for collaboration and efficiency. As industries adapt to the ever-changing landscape, these innovative tools are emerging as game-changers, enhancing human workers’ capabilities and unlocking new productivity frontiers.
One of the key aspects of these technologies is their collaborative nature. Cobots, for instance, are designed to work alongside humans, seamlessly integrating into existing workflows. This fosters a symbiotic relationship between man and machine, enhancing productivity while ensuring safety and precision. This collaborative approach reassures the workers that these technologies are not meant to replace them, but to enhance their capabilities and make their work more efficient.
Technologies such as wearables are equipped with advanced sensors and augmented reality interfaces that empower workers with real-time insights and enhanced capabilities. From providing hands-free access to critical information to facilitating remote guidance and training, these wearable technologies are revolutionising how tasks are executed on the shop floor. As industries embrace these transformative technologies, they are poised to unlock unprecedented efficiency, agility and innovation, ushering in a new era of workforce empowerment in industrial automation.
Easing the load with autonomous mobility solutions
Material handling can account for 25 per cent of the workforce, which is incredibly challenging in the era of a global labour shortage. According to the Manufacturing Institute, part of the National Association of Manufacturers (NAM) in the US, while 4.6 million new manufacturing jobs are projected to be created by 2028, 2.4 million could go unfilled. By automating the dull, repetitive task of material handling with AMRs, manufacturers can reallocate the limited available labour into more fulfilling roles that better utilise uniquely human skills and often come with higher pay.
AMRs have been disrupting the material handling industry for over 50 years. Increasingly, manufacturers are implementing this innovative technology to improve flexibility, efficiency, safety and usable floor space. By understanding the benefits of AMRs, manufacturers can make an informed decision to adopt the technology.
However, despite some commentary, smart manufacturing technologies like AMRs are not replacing the workforce but enhancing it. According to The State of Smart Manufacturing report, 94 per cent of manufacturers anticipate hiring more employees or reallocating them to new roles with increased use of these technologies, a rise from 89 per cent in 2023.
Real-world success stories further underscore the potential of automation technologies. For instance, Mauser Packaging Solutions, a global packaging leader with over 180 facilities worldwide, integrated AMRs into their operations, effectively addressing labour shortages at two facilities. By deploying OTTO Motor’s AMRs to transport finished goods to stretch-wrappers, Mauser was able to free up three labourers for higher-value roles, resulting in a staggering 600% throughput boost. This is a clear testament to the tangible benefits of automation in enhancing productivity and efficiency.
Today’s successful manufacturers are empowering their workforce to adapt to evolving environments. Employees become equipped for modern manufacturing settings through training on updated processes, where they collaborate with smart technologies. Technologies like AMRs handle unsafe, repetitive tasks, allowing workers to focus on high-value, fulfilling responsibilities that leverage their unique human skills. Proactive workforce preparation ensures better retention and engagement amidst technological advancements.
The rise of the cobots
Cobots, short for collaborative robots, have rapidly gained traction as versatile assets in modern manufacturing environments. Unlike traditional industrial robots confined to safety cages, cobots are designed to work alongside humans, offering a collaborative approach to automation. With their advanced sensors and built-in safety features, cobots can operate safely near human workers, reducing the need for physical barriers and enhancing flexibility on the factory floor.
These collaborative robots excel in various tasks, from assembly and pick-and-place operations to quality inspection and packaging. Their ease of programming and adaptability make them ideal for small-batch production and rapid changeovers, enabling manufacturers to respond swiftly to evolving market demands. By augmenting human capabilities rather than replacing them, cobots enhance productivity while ensuring a safer work environment. As a result, they have become indispensable tools for improving efficiency, reducing errors, and streamlining workflows in modern manufacturing operations.
Integrating wearable technologies
Enterprises find value in the physical, digital and human convergence created by augmented reality (AR) delivered through wearable devices. AR is a critical factor in helping companies unlock the value of digital transformation. There continues to be significant research on the impact of AR in industrial settings, with industry analysts such as ARC Advisory Group and Aberdeen Group highlighting the importance of AR in improving service and manufacturing processes in industrial enterprises.
Extended reality or XR technology encompasses virtual, mixed and augmented reality and is a powerful tool in training and retaining employees. HoloLens, RealWear tablets and smartphones are tools that empower workers with knowledge transfer using AR expert guidance. With VR-enabled work instructions and a digital twin, you can train workers with remote assistance, increasing efficiency, productivity and safety.
On-site remote support helps maintenance personnel get support when they need it. With AR remote assistance, the subject matter expert can visualise what is happening remotely and allow the technician to correct the issue using remote visibility. AR is also used to help train new employees with remote assistance and work instructions. Video training for employees allows them to retain more effectively than even in a classroom setting and is also easier for language translation if required.
The impact on technology investment
As Industry 4.0 continues to shape the manufacturing landscape, investment in cobots, AMRs, AGVs and wearables is propelled by several key factors. Firstly, the need for increased productivity and efficiency drives manufacturers to adopt automation solutions that streamline operations and reduce manual labour costs. With their ability to collaborate safely alongside humans, cobots offer flexibility and versatility in various tasks, further enhancing productivity.
AMRs and AGVs address the demand for optimised material handling and logistics, enabling seamless movement of goods within facilities. Their autonomous capabilities minimise human intervention, leading to faster and more efficient workflows.
Focusing on worker safety and ergonomics is crucial in driving investment in wearables. These devices, equipped with sensors and monitoring capabilities, enhance worker safety by providing real-time alerts and insights, thereby reducing workplace accidents and improving overall efficiency. Overall, the convergence of Industry 4.0 and the pursuit of operational excellence propels investment in these transformative technologies.
A bright future outlook
The trajectory of industrial automation technology suggests a profound transformation in the future of work. As AI, machine learning and robotics advance, further integration and adoption of cobots, AMRs, AGVs and wearables across industries is inevitable. This integration will facilitate a paradigm shift in how industries operate, and workers engage with technology.
With their collaborative capabilities, cobots will enable seamless interaction between humans and machines, enhancing productivity and safety on the factory floor. AMRs and AGVs will revolutionise logistics and material handling, optimising workflows and reducing manual labour.
Wearables with advanced sensors and monitoring capabilities will enhance worker safety and performance while providing real-time insights for better decision-making. As these technologies become more sophisticated and accessible, industries will experience increased efficiency, agility, and innovation, reshaping the future of work and empowering workers to thrive in an increasingly automated environment.
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