I work in the automotive division at Kawasaki Robotics, and I’ve worked directly with a whole lot of products in our lineup. All of them are trustworthy and capable, so it was hard to narrow it down to just five.

But we got there. Here are a handful of our notable difference-making robots, spanning applications from automotive to far beyond.

1. BX200: The All-Rounder

KEY SPECS

• Payload: 200 kg (440 lbs)
• Max reach: 2597 mm (102”)
• Mounting: Floor

APPLICATIONS

• Spot Welding
• Material Handling
• Machine Tending

I’d call the BX our workhorse. Its hollow wrist is perfect for housing cables and hoses, and the strong and lightweight arm makes it ideal for spot welding. So spot welding is a key BX application, but really, it’s tough to pin down just one because of how versatile it is.

I’ve seen the BX used in material handling (the payload capacity is a good size for automotive), machine tending and dispensing, applying sealants and inspection. You can mount a camera on the BX, and it can go to a specific location and compare the data it sees with your model. Excellent for error-proofing.

2. MG15: The Power Lifter

KEY SPECS

• Payload: 1500 kg (3,300 lbs)
• Max reach: 4005 mm (157”)
• Mounting: Floor

Lovingly referred to as Mega Godzilla around these parts, the MG has a surprisingly small footprint despite its impressive size. It uses a ball screw and nitrogen gas cylinder counterbalance design, and special kinematics with 11 swivel points for robot motion and weight distribution, plus 9 motors. Put simply, this 6-axis robot lifts 3,000+ pounds the same way you and I lift our computer mouse, and it does it with 0.05 mm repeatability.

You could give it some spot welding, but it’s not really designed to do that work. The key application for the MG is, without a doubt, material handling. This guy is heavy-duty. We originally designed it for aerospace, but we quickly got a whole lot of requests because of its payload. Customers get not only the ability to lift serious weight; they also get a robot that’s more accurate than they may ever need. The ball screw design makes it very rigid and repeatable.

3. CP 700: The Stack Master

KEY SPECS

• Payload: 700 kg (1,540 lbs)
• Max reach: 3255 mm (128”)
• Mounting: Floor

Being in automotive, this is the one robot on today’s list that I haven’t used. But I’ve heard and I know plenty about it, because it’s a top performer in palletizing.

If you need packaging and stacking, you’ll love the CP. Good payload with impressive speed and very easy-to-use palletizing software.

4. BA013N: The Welder

KEY SPECS

• Payload: 13 kg (29lbs)
• Max reach: 1492 mm (59”)
• Mounting: Floor

As you can tell from the specs, this is a compact and precise robot. Its key application is arc welding, so the heaviest thing on it is sure to be an arc welding torch.

I’ve worked with a lot of welders in my day—and also with a good amount of competing robots thanks to my history as an integrator—and it’s clear that the BA shines because of its feature set. This is probably the most user-friendly and feature-rich option in its category.

5. BU015X: The Seal of Approval

KEY SPECS

• Payload: 15 kg (33 lbs)
• Max reach: 2887.5 mm (113”)
• Mounting: Floor

A sealing robot that sports a 7th axis. Especially useful for getting to places that are hard (or impossible) for 6-axis robots to reach, like the underside of car bodies.

The key perk with the BU is that, rather than having sealer dispensing from a third-party supplier, this robot is fully Kawasaki: seal pump, material and everything else. So if you have a desire for an all-in-one sealing robot, the BU is perfect. It’s all packed in.

No matter your robotic application, there’s probably a Kawasaki robot for it.

Regardless of industry, task or payload, Kawasaki Robotics is known for building and supporting strong, intuitive and versatile robots. Whenever you’re ready, talk to us about your application.

It’s already quite the challenge, but when you factor in staffing issues that persist across manufacturing, that challenge quickly morphs into a problem. How are packaging and palletizing companies supposed to keep pace?

One good answer: robotic automation. And for shops in need of such a solution, they typically find Kawasaki Robotics to be especially helpful, intuitive and sustainable..

This is why the CP Series is such a standout. There are many reasons our high-performance palletizing robots are an ideal choice for your next addition. We’re covering several of them today.

1. Speed Meets Strength

Nova Automation, a prolific robot automation expert and one of our integrator partners, simply refers to the CP Series as its workhorse. With a wide-ranging 180 to 500 kg (397 to 1,102 lbs) payload capacity and industry-leading cycle times, it’s clear that the reputation is justified.

The CP Series has the speed and strength necessary to accomplish serious palletizing work in short order, over and over again. It has a maximum reach of 3,255 mm (128”), plus an industry-best palletizing capacity of 2,050 cycles per hour at a 130 kg (287 lb) payload using the CP180L model.

2. Space and Energy Conservation

The E03 controller attached to the CP Series is an undisputed winner as well. The space- and energy- saving unit is just 25% of the standard palletizing controller size and easily fits under conveyors and other equipment.

This controller generates electric power while in a deceleration mode, reducing energy consumption and minimizing carbon dioxide emissions. It’s a guaranteed way to boost sustainability in your shop as you boost productivity at the same time.

3. That Intuitive Software

Kawasaki Robotics’ software is known to be more open and possibility-filled, and it’s fun and easy to use, too. Our dedicated palletizing software, available as an option, allows users of varying skill levels to quickly and easily simulate layout planning and operations. They can also create robot operation programs on a computer.

4. Our Legendary Support

While our robots, controllers and software have proven themselves to be consistent difference-makers, the team at Kawasaki Robotics has done the same thing. We work hard to be a partner who shoots straight, treats people right and lends exactly the right consultation. There’s a reason we like to say WE ARE NOT ROBOTS, after all.

5. The CP Series is In Stock!

We have a handful of CP units on our floor right here in Michigan, and they are ready to serve. If your business has a need for palletizing you can set your watch to day in and day out, there’s nothing better. Explore the CP Series further or get in touch with us. We’re ready to equip you for today and tomorrow.

In my previous roles, I mostly worked on FANUC robots. I was comfortable and didn’t think I needed to know much else. Then I joined Kawasaki and discovered a whole new world of access thanks to a different, more freeing programming language.

It made me realize I could make our robots do a whole lot more than I could make them do before. Kawasaki has a very open programming language that has a lot in common with computer software. If you like having lots of commands to build different functions, you’re going to love the Kawasaki software.

As you get started with Kawasaki Robotics software, here are 10 tips to keep in mind that will help to quickly gain fluency in this new and exciting language.

1. Create Robotics Programs Offline

K-ROSET is our sim software that lets users troubleshoot, learn and improve. Create robot programs offline and see a 3D version of your robot run your program. Our LITE version of the software is a free way to start using basic features of K-ROSET. You can contact us anytime to get the free version.

2. Access Comprehensive Notes

Kawasaki Robotics has a web page filled with robot manuals, software manuals and training and marketing content. Everything is vetted by our headquarters in Japan, so you can be sure you’re completely up-to-date as you absorb the material. To get access, get in touch with your Kawasaki sales rep.

3. Get More For Less

Long-time Kawasaki Robotics customers know this well, but newcomers are often surprised to learn just how many software options are packed in without requiring additional cost. Collision detection is a big example of one such option. It does exactly what you think: slows and stops the robot before making contact, preventing damage.

4. Monitor the Location of the Robot Tool with Work Zones

Automatically turning on an output lets the controller know that the robot has entered an area of the system, which proves useful when multiple robots are in the same zone. They’re able to tell each other where they are.

5. Get More Consistency with Direct Speed Control

DSC lets you control movement speed in mm/sec instead of as a percentage. So if you want your robot to go 130 mm/sec when it goes to dispense or approach a pick position, you can do that. It’s great for a constant and controlled speed.

Whenever You Have Questions, Bring Them to Kawasaki

All of us at Kawasaki Robotics only know one way to do business: stress-free, collaborative, and with mutual respect. As you build your long-term robotic process automation strategy, we’re always here to help however we can.

6. Solve Singularity Positions

A major problem industrial 6-axis robots have is when joints 4, 5 and 6 are aligned. This is solved with a single line of code in the program that locks joint 4 to zero degrees for specific motion paths. This solution isn’t very well known, but it works wonderfully.

Fun fact: tips 3 through 6 are all included standard in the Kawasaki controller!

7. Capitalize on Background Programming

All robot programs, regardless of brand, go line by line. But at Kawasaki, we also use background logic that runs on the side of the main programs. Handle communication with the PLC, run error handling on the side, and in general, enjoy more logic overall. When people say Kawasaki programming is flexible, this is a big reason why. It’s also why we typically say yes when a customer asks, “Can I do this?”

8. On I and On E

These functions monitor input in the entire robot motion. For On I, as soon as the input turns on, the robot runs a different function. On E is the same, except it’s on error. So as soon as any error happens in the controller, that specific function is run. If there’s a collision or the program faults out, this function talks to the PLC and gives an explanation for what happened.

9. Got a USB Stick or Ethernet Connection? Grab Your Robot Backup.

All programs, system settings and robot configuration, saved in a single text file. You don’t need a special license to read the backup, either. Just take the drive, plug it in and read every program, error log and robot config that’s in there. It’s about 500 kb per text file. Then, plug the backup into your next robot to speed up integration in a big way.

10. HMI Screen, Standard

Every Kawasaki teach pendant comes standard with an HMI screen. It’s usually a costly device like an external PC or table touchscreen on the outside of a cell. But here, that functionality is on the teach pendant itself with the teach pendant touchscreen.

Ready for a Whole New Programming World? Talk To Us!

Kawasaki software might be the most open and possibility-filled option on the market. To see all the additional things our robots are capable of thanks to their programming, talk to us about your application.

Hang on there. Before you leave this page, let me just say I know what you’re thinking: an entire article about long-term robotics strategy? YAWN.

For the record, I fully agree with you. The manufacturing and industrial robotics sectors tend to get ridiculously technical in stories like these, publishing content that’s dry enough to make farmers panic.

It’s funny that so many of us do it that way, isn’t it? Especially considering people often need conceptual instruction rather than reams of technical info.

So yes, this is indeed an article about building a long-term Robotic Process Automation (RPA) strategy. But this one is actually readable, and you might actually take away a couple things.

Rule #1: Start Simple, Start Small

If you’re just starting to work with industrial robots, remember to focus on the basics and the fundamentals. When kids learn baseball, they don’t immediately learn how to hit the cutoff man and throw a slider. They learn where first base is.

It’s the same with any new endeavor. The best (and most cost-effective) way to learn is to start simply and know that you’ll grow your knowledge over time. I’ve seen plenty of horror stories where a company said goodbye to a thought-out robotics strategy and instead dropped seven figures on their first project.

It’s a much wiser move to spend somewhere between $100k and $200k on that first project. After all, you don’t know what you don’t know. You and your team will learn what works best for you that you can take to future projects. Trust me on this one: you won’t know what you want from your first robotic system until after it’s running.

Whether it’s a DIY project or you’ve partnered with an integrator, know that you don’t have all the experience you want yet, and that that’s okay. Each project is a chance to position yourself better for the future.

Rule #2: Diversify Your Robotics Portfolio

This one is HUGE, and the basic truth goes beyond robotics. No matter what the industry is, we all tend to have strong loyalties for certain brands. It’s scientifically impossible to see a Mac user operate a PC without complaint, and vice versa.

In industrial robotics, whether your favorite jersey is yellow or red, a lot of us tend to leave that jersey on and never take it off. But in all honesty, you are doing your company a disservice if you do business that way.

Do I want to see you buy Kawasaki Robotics? Of course! That’d be great. But if I was your brother and you asked me if you should diversify your robot base, I’d give that question a big ol’ affirmative.

Here’s a quick list of pros and cons:

Pros of working with multiple robotics partners

• Protect against shortages
• Keep your suppliers honest
• Get the best deal
• Give employees more comprehensive training
• Move eggs to other baskets
• Benefit from engaged and motivated partners
• Foster rational decision making
• Harness partner strengths and avoid their weaknesses

Cons of working with multiple robotics partners

• Your floor will lose some of its color coordination
• End of list

You diversify your stock portfolio and know that practice to be a wise one. Why not do the same for your business and diversify your base of supply?

Rule #3: Training Needs to Happen Now and Later

Once you’ve chosen your robotics platforms (yes, plural), it’s time to get your people trained. Teach them the basics, and instill into your culture that no one company has a monopoly on the tech you use. Train them on PLCs like Siemens, Allen-Bradley and Omron. Train them on robots like Kawasaki (the best choice in my unbiased opinion), FANUC, ABB, KUKA or Yaskawa.

Doing it now is easier than later, when you have a massive base in place and you’re scrambling to teach everything. Start foundational, progress to advanced and lay the groundwork for long-term sustainability.

Rule #4: Know What You Want from Robotics Integrators

Two options here. The first is doing a lot of it yourself and bringing on an integrator in a consulting role.

They should have experience. They should have successful projects under their belt. But they should also fit naturally with you and your company culture.

Find out what they specialize in, what they’re good at. Partner up with the integrator consultants whose skills and experience match what you’re looking to do.

Find out what size of projects they like to work on. Find out how many programmers and engineers they have. How many mechanical, electrical, PLC experts on staff. This gives you an idea of what their resources are like.

Finally, ask them straight up if consulting is something they’re interested in. If they are, it’s off to the races.

So that’s option one. The second option is the full integration partners that do it all for you. It’s still important that they align with you culturally, but now it’s vital to focus on the application.

If, for example, you know that you’re only going to be palletizing, you may not need more than one integrator partner. But if you plan to execute a variety of projects, you’ll probably want more than one in the stable.

As you work with them, you’ll notice that Integrator A is really good with this specific application. Integrator B brings a ton of expertise, but they’re too expensive for the simple projects.

Looks like I went back to diversification again. To be fair, I can’t help it. It’s clearly the smartest way to do it. The more integrator partners you get to know now, the more you’ll understand their capabilities for future projects.

Whenever You Have Questions, Bring Them to Kawasaki

All of us at Kawasaki Robotics only know one way to do business: stress-free, collaborative, and with mutual respect. As you build your long-term robotic process automation strategy, we’re always here to help however we can.

Talk to us anytime. Doesn’t matter if you already have a robotics partner. We’ll gladly contribute to your diversified portfolio.

I encounter this question often enough over the course of my week that I figured I’d park it in the chair and write a full guide. If you’re wondering what the difference is between fixed automation and flexible automation—and which is the best fit for you—get ready to scroll for a bit.

What Is Fixed Automation?

Put simply: fixed automation, also known as hard automation, is automation without a robot. It covers anything that is generally not flexible to changing orientation, adapting for multiple SKUs, or programmable as a single unit.

Instead, fixed automation is a system using servos, standalone servers, linear or rotary actuators, separate sensors, and programmable logic controllers (PLCs) all integrated into one system.

Benefits of Fixed Automation

Want to go fast above anything else? Fixed automation is for you. It tends to be faster than any other option. We robotics folk don’t love to admit that it’s faster than robots, but it’s true. Go to tradeshows and see actuators, they’re moving at wild speeds. I’m talking sub-one second cycles.

On top of the speed, actuators and servos are available and relatively cheap. A lot of footprinting is standardized as well, and it’s easy to plug & play with a lot of different fixed automation components.

A couple more perks while we’ve got momentum: simplicity and robustness. A good PLC programmer doesn’t have to break a sweat to get fixed automation doing what it needs to do. It’s not overly complex. And in terms of robustness, breaking a part generally isn’t a huge deal because you probably have the spare part on the shelf.

Bottom line: good variety of product to choose from, fairly low cost, simple and robust, and mood-boosting speed and accuracy. Fixed automation is a great option for some. But not for all, because:

Weaknesses of Fixed Automation

Pretty simple: it’s not flexible. You might be able to move things a bit, but if flexibility is a key need for your application, you’ll have to look elsewhere.

We just mentioned that fixed automation is fairly easy to program, but the build of the fixed automation system itself can be tremendously complex. What’s more, there’s no manual for that system. The only people who know how it was set up are the people who built it in the first place.

Flexibility is honestly the biggest downside of fixed automation. But wouldn’t you know it, there’s a fantastic option for anyone who craves that flexibility.

Benefits of Flexible Automation

By now you’ve guessed what the key benefit is here, but I’ll say it anyway: that flexibility. Having the ability to use one robot on different products is a huge plus, and for high mix low volume environments, it’s downright huge.

As the years have progressed and robots have improved, their durability and robustness have grown to mimic fixed automation. They don’t tend to break unless accident or neglect happens. Their repeatability is good, but not as strong as some actuators. Flexible automation has too many things pulling other things around, and last I checked, physics is undefeated.

HOWEVER. For your application, you may not need repeatability as much as you need flexibility. Complete a job, and you can easily move that flexible robot to the next task. It’s a game-changer for HMLV facilities.

Weaknesses of Flexible Automation

Even the shiniest and toppest-of-the-line robots are bonafide boat anchors until someone tells them what to do. And programming that robot to capitalize on its flexibility takes real work.

But the good news is once you tell the robot what to do, it’s going to do that job consistently and without complaint for as long as you need it to. A robotics partner worth your time and budget will also provide with all the training materials you need to speed up the learning curve.

And of course, if speed is important, flexible automation might not be right for you. A good rule of thumb: if you want to move something heavier than 5 pounds in less than 5 seconds, flexible automation is probably too slow.

Where to use Fixed Automation

Use fixed automation on long runs of consecutive single-SKU or dual-SKU products that run for a REAL long time doing the same thing, over and over.

Couple examples: row after endless row of oil filters or food packaging coming off a conveyor line. Pick ‘em up, put ‘em over here.

A very real possibility: you might need both

We’ve implemented plenty of systems where flexible automation works closely with fixed automation. A whole lot of facilities see major benefits from doing what each system is good at: they get the speed and cost-effectiveness of fixed automation, combined with the flexible nature of robots.

Closing

You may already know this answer based on your application, but here’s the key question: which do you need: speed and repeatability, or flexibility? That answer will tell you whether you should pursue fixed automation or flexible automation.

If you have additional questions or want to know more about an application-specific offering from Kawasaki Robotics, contact us any time. We love nothing more than talking this stuff over.

The NOVA Start

NOVA Automation got its start in the mid-1990s when the founders had the urge to return to Denver and serve a customer base that wasn’t being fully taken care of. The reason for starting the company then was the same as the vision now: to give the packaging industry robust and durable industrial automation.

“We started in palletizing, and we’ve since grown into bag filling, stretch wrapping, and conveyance,” said Paul Wegman, CEO of NOVA Automation. “The end-to-end systems we build are incredibly robust.”

“When my business partner and I purchased the company in 2018, we did so because it was such an exciting opportunity. The NOVA products and projects were a solid foundation, and there was an opportunity to make things even better. Today, we’ve simplified our machines to make them very easy for less experienced operators to run.”

The NOVA Difference

NOVA stands out from other automation providers in a couple of ways. The first is something Wegman covered. “We’re an end-to-end manufacturer here, meaning every product that ships out of our facility, we control the design, the manufacturing, the control system, the testing, all of it. So, we have incredible flexibility to respond to customer needs. We can do business at a pace that’s much faster than others.”

The second difference-maker is one we’ve noticed firsthand on a regular basis: NOVA truly listens to customers and partners. Not only does this practice help to build long-lasting relationships, it also guides the kind of product innovation that’s only possible when you’re paying close attention.

The Mobile Palletizing Cell

For proof that NOVA listens and responds better than most, look no further than the company’s MPC Series. “What we were hearing from the market was that there was a need for collaborative robots in palletizing,” Wegman said. “But in speaking to customers, it didn’t make much sense. What they actually needed was a stronger and tougher industrial robot, but also with a small footprint that was mobile and easy to use.”

The MPC Series was developed and launched as a result. Plug, Play, Profit is the language NOVA uses to market the product, and it’s no joke. The programming is already done before it arrives, and it’s paired with an intuitive user interface with an HMI that’s ready to go—plus the NOVA Pallet Builder, which lets users build new pallets on the fly without touching the robotic pendant. It’s a fully enclosed and forklift-moveable cell, ready to rock right when it comes off the truck.

“A person is never going to help a robot palletize, so people didn’t need cobots, as it turns out. They needed industrial strength and speed in a small form factor that was easy to set up and operate,” Wegman said.

Kawasaki + NOVA

NOVA has used Kawasaki Robotics offerings for many of its product lines for close to 15 years. Wegman didn’t discover what Kawasaki was all about until later, but the symmetry was immediately apparent.

“I knew a lot about Kawasaki as a motorcycle and ATV manufacturer, but I didn’t know they were in robotics until I got to NOVA in 2018,” he said. “What I learned was, Kawasaki makes an awesome product we’ve had a great track record with.”

“But what really makes them different is the way they support us and our customers. They really do treat us like we’re their best customer. That support we get is far more important to me than just having a great product.”

Kawasaki’s CP Series: NOVA’s Workhorse for Palletizing

NOVA specializes in solving complex packaging automation challenges for customers who have a wide range of speed and product demands. Robust robotics solutions require robust robots, which is why the company leans heavily on the CP Series of palletizing robots from Kawasaki.

“The CP series is our workhorse,” said Wegman. “It’s a robot we’ve been selling for over 12 years that has stood the test of time in the harshest environments and continues to perform day in and day out.”

The CP Series sports an impressive payload capacity, plus industry-leading cycle times, a maximum reach of over 3 meters, and a 2,000+ cycle-per-hour palletizing capacity. Its versatility makes it an ideal fit for palletizing, where customer needs vary widely.

Building the Culture

On the subject of how NOVA stands out from other manufacturing companies, Wegman and his colleagues have worked hard to build a business with a healthy, collaborative environment that people want to return to.

“First of all, it’s just fun to see everything that’s going on here on a daily basis,” he said. “Go on our floor today and you’ll see seven projects being tested with robots running. Our team isn’t making 10,000 widgets per day, either. They actually get to see the product from start to finish, then again in the real world.

“We also try to bring in a lot of compassion, awareness, and mindfulness. These past few years have been hard in a lot of ways, so we brought in a certified mindfulness teacher to show us how to meditate, and to teach some compassion and vulnerability exercises. It makes for pretty powerful moments, and we still use the exercises here on a regular basis.”

The Future of NOVA

“We’re at an awesome and exciting spot in our journey. We’ve proven that our processes can scale and are profitable, and we know now that this is a viable business that’s ready for even more growth,” Wegman said. “A building expansion, growing our staff, finding more space in Denver to build and test, all of that stuff is on the table.

“When I first started here five years ago, people still saw us as job killers. But now it’s shifted. Companies can’t meet their output needs alone, but we can help with that. We’re taking people out of dirty, harsh environments that are prone to ergonomic injuries and giving them the freedom to pursue better, safer jobs within their company.”

One thing we know for sure: NOVA will be listening closely and developing industrial packaging solutions that actually solve a need that manufacturers have. It’s why we’ve worked with them for so long, and why we’ll work with them for years to come.

If you, like NOVA, have a clear need for high-speed industrial palletizing robots, read up on the CP Series from Kawasaki. We have robots in stock and ready to unlock automation benefits at your facility.

Taking that first step into robotic automation can be intimidating. If you’ve deployed systems in the past that can certainly help blunt the edge, but even then it can still be nerve-wracking. After all, in most cases you don’t get to buy a fully researched system that has been tried repeatedly in the same way that a press brake, table saw or car has been. You are most likely buying a completely customized system with several components made by different OEMs.

Robotic automation projects can be expensive, and if you sold this project to upper management – or maybe you are upper management – then your credibility is kind of on the line as well. In order to get the most out of your money, you want to make sure you work with experts who understand your application and industry. So, what is one to do in these scenarios? As The Ghostbusters so aptly asked: Who you gonna call?

Of course, nothing is zero risk. But there are things you can do when you’re getting started to increase your probability of success. In this article, I will guide you on what to expect, how to proceed and how you can limit your risk in your first outing with robotic automation.

Rule 1: Start Small

The first rule is simple. Don’t take your biggest, most complex problem (or headache) and set out to automate it right out of the gate. While I know this is tempting, it’s important to focus on something that you can bite off and chew a little easier.

Why? Completing a robotic automation project is a bit like building or remodeling a house. You lay out your vision, get a plan and then it’s all supposed to come together. What you learn are things you didn’t realize you’d have to learn, such as how one subcontractor is better or worse than another and for what reasons. Just learning who you can trust to do good work and who to call is a learning curve in and of itself. If you start with a big project, you will likely be more exposed financially, but you are also far more likely to be overwhelmed by what you didn’t know you didn’t know

Small projects allow you to take a lower-risk approach to getting robotic automation into your facility. Remember; automating your processes is a journey, not a quick trip. The more you do it, the more your processes and other manufacturing elements are likely to evolve along the way. Starting with something small and simple allows you to limit your financial exposure, get some experience with the process of working with an integrator and get some confidence and knowledge under your belt.

It’s true: the ROI or pain reduction by this process might not be as epic as the big process you have in mind, but you will be that much more ready for that big one after tackling some smaller projects first.

Rule 2: It May Cost More Than You Think

It’s not the most popular thing to say, but it’s the truth.

Don’t get me wrong, if you have a simple palletizing or material handling application, your price tag may be lower than you expect. In my experience, most people tend to have an application in their mind and a price tag associated with it. When I was an integrator and I ran into this kind of disposition, I would investigate to see what was driving that idea of the cost. Usually, I found it was pretty arbitrary. I would then have to gently guide the customer towards a more realistic expectation for the cost of the system.

As a general rule, unless you have a really good feel for this kind of pricing, you can expect that the system will probably be more expensive than you think. Take heart though, so long as you are choosing the right integrator (more on that in just a bit), this is more likely to mean that your money is being well spent. Just be prepared for a little bit of sticker shock when you get your bids back.

Mind you, it’s completely acceptable to ask an integrator for an estimate or budgetary bid prior to them working out a whole detailed quote. Believe me, they will appreciate your honesty and respect for their time as much as you will appreciate the information.

Rule 3: Make the Integrator Show You Before You Buy

Unless your application is extremely simple, I would suggest you ask that the integrator show you as much of a concept as is reasonably possible (layouts, simulations, etc.) prior to signing an agreement. This is pretty standard in the industry and something you can reasonably expect.

The integrator will usually try to render something so you can confidently understand what they are planning without going to the point of advanced or detailed engineering. Also, most integrators will propose a budgetary scope to you before they put any time into even conceptual layouts or drawings. As long as you tell them that the budget they’ve proposed is within your tolerance levels and you have a serious interest, then they will proceed down the more labor-intensive path of a detailed proposal. These proposals will usually include layouts, some basic renderings of the concept solution, key performance metrics, key features, etc.

There’s no real hard standard for this, as each integrator is likely to take their own kind of approach as to how much detail or not they put in a proposal and how they organize it. What you’re really looking for is an integrator that jives with you. Once you start looking through the proposals (and it’s completely fair to get as many as three), your instincts will tell you who has the goods and who isn’t a great fit for you.

Rule 4: Don’t Sweat the Small Stuff…But Sweat Some Small Stuff

Unless your application is extremely simple, I would suggest you ask that the integrator show you as much of a concept as is Especially if it’s your first system, it can be easy to get hung up on some of the simpler stuff that really doesn’t much matter in the end. One of the biggest things I used to see people get in a pinch about was what brand of HMI, PLC, camera, sensors, etc. was going to be in the system.

While your maintenance people may have a strong, and even justified, opinion on this, the likelihood is that it doesn’t matter all thI know that can sound like sacrilege coming from a robot salesman whose job it is to differentiate from other robot makers. However, the advice is sound one way or another, and if I’ve convinced you along the way that you should be using a Kawasaki robot (which you should 😊), then I will answer any questions that the integrator has, and address any information they feel is missing.

But when it comes to pressing the buttons on the HMI, are you really going to care what brand it has on the plastic bezel around the frame? That’s what the service from the people who built it is for. Unless you went looking, would you know whether the prox sensor on the conveyor was a Turck or an IFM? Would you care? Those are details that, in my opinion, aren’t necessarily worth the worry.

On the other hand, you may want to know how the HMI is going to be set up to choose different recipes or change system settings. That’s the kind of detail that is worth hashing out ahead of time, as the user interface is one place where people can really have some regrets or love affairs. Will the system be on a steel frame or extruded aluminum? Does it make a difference to you? Is there a cost advantage? Will you own the design when the project is complete? These are the kinds of details that might be worth thinking about to make sure that you are happy with the entire system when it’s all said and done.

Rule 5: Have an Open Mind When It Comes to Hardware Brands

This is easier said than done, in almost all facets of life. I’m building off some of the input in rule #4 because I think it’s prudent. Different integrators have different skill sets and familiarity with different brands of equipment. When I was an integrator, we used Kawasaki almost exclusively. The key reasons for that were threefold:
· The openness and ease of programming
· The lack of proprietary lock-outs and nuisance fees
· Their top-notch support

All of the above, combined with remarkably competitive cost, created a value offering that was far and away better than we could offer with any other robotic automation brand. With that said, we would sometimes go to a customer who just insisted that we had to use their specified brand of robot, PLC or other hardware. We would explain to them that we could not only offer the system much cheaper with our preferred brands, but that we had better confidence in its reliability and maintainability as well. This isn’t just about cost; I’m a firm believer that you get what you pay for. What is easy to forget is that you can also find yourself paying for a lot that you don’t get.

This is about maximizing value. There were times when the customer’s insistence on a certain brand led to extended lead times, lack of backward compatibility, or even missing out on excellent value-added features that were all in line with the hardware we originally recommended.

If you are really committed to a certain brand for some reason, I’m not here to tell you that you shouldn’t be. After all, I’d love to see everyone using Kawasaki, and I think I can justify why they should. What I’m here to tell you is to have an open mind when it comes to these things. If you’re beholden to a certain brand and your integrator isn’t comfortable with it, put the onus on a representative like me to allay that lack of comfort with the integrator on your behalf. That’s what we do. But if your integrator is suggesting a brand to you that you weren’t aware of or maybe lack familiarity with, hear them out. You don’t know what you don’t know, and you might be surprised by some of the value-added advantages that are available from a brand that’s new to you.

Want to know more?

This all just scratches the surface of things to consider when getting started in automation. A person could probably write an entire book on that subject alone. If you want to shortcut all of that, maybe give the experts at Kawasaki Robotics a call. Something tells me we could help you out.

Please note the views and opinions expressed in this blog belong exclusively to the content creator, not to Kawasaki Robotics as an organization. The content of this blog post or any user content it generates in no way conveys the thoughts, sentiments or intents of the organization.

But when it comes to actually implementing a robot, a lot of questions arise. “What tasks can you leave to the robot?” “What steps do I need to take?” “Who should I talk to in the first place?” Here are some of the best ways to take industrial robots from concept to reality.

Consult with Professionals

You’re starting at square one: No robots have been introduced yet. You are interested in automation, but not sure which tasks to automate. In the beginning, it can be difficult to judge whether a particular task can, or should, be automated or not. In this situation, there are resources to give you peace of mind when introducing a new robot system. In many cases, a specialized engineering firm called Robotic System Integrator (robot SIer) is responsible for planning, designing, and deploying robotic systems. In general, the SIer interacts between the user and the robot manufacturer, acting as a connection between them, and leads the way to the system installation. Kawasaki is a valuable robot maker that can even play the role of a robot system integrator.

Let’s take a look at the flow from the introduction of robots to installation. (An example of a basic flow is shown in Fig. 1.) In the early stages, the system integrator will conduct preliminary meetings and field observations to gain a better understanding. It’s important to know what the end-users are looking for and what’s going on in the industry, as well as basic requirements like budget, schedule, cycle time requirements, specs, variety, workspace, etc. Building a robotic system is a collaborative effort between the end-user, system integrator, and robot manufacturer, and a thorough understanding of the requirements is essential for success.

Create a robot-conducive environment

Next, you need to understand whether or not automation should be used. Robots are better at some tasks than others. For example, it is easy to accomplish repetitive tasks that require high degrees of accuracy, or dull, dirty, and dangerous jobs that aren’t ideal for humans to execute. But when it comes to complex applications requiring human senses such as sight, delicate touch, smell, and taste, extra equipment and sensors may be required, which can make a system more complicated and expensive. It is important to consider whether a robot is really suitable for the process you’re thinking of automating and whether a robot can demonstrate its power, productivity, and cost-effectiveness.

Even in the common case of partial improvement of production processes, the first step is to sort out the tasks that should be performed by humans and the processes that should be performed by robots, taking into account the above viewpoints.

After narrowing down the processes to be automated by the robot, work elements are disassembled in a way that makes sense for the robot. For example, a person might think of a task the following way: Remove the screw and place it on the product on the jig. When you finish tightening, put the finished product in the next box. But in the case of a robot, it is necessary to subdivide each task:
Step 1: Remove the screw
Step 2: Place the product on the jig
Step 3: Place screw in the designated location
Step 4: Tighten screw
Step 5: Pick the finished product
Step 6: Place finished product in box

At this point, it’s easy to overlook the details of the human worker’s movements. For example, turning the parts inside out when placing them on a rack, visually checking the product for foreign objects, or tapping the surface to check the sealing performance are all simple but important movements. Once a robot is made to do the detailed work that the workers are doing almost subconsciously, it is necessary to construct a system not only for programming each and every operation but also for linking the tools used and the processes before and after.

At the same time, it is essential to create an environment in which robots can operate.
For example, if there is no storage space for equipment needed before and after the automated process, there is no problem in the operating space of the robot itself, but the process could be delayed. It is very important to design while imagining not only an automated process but also keeping in mind a realistic process flow such as whether this equipment is smoothly linked to the tasks that come before and directly follow that process. This requires a macroscopic perspective with a bird’s-eye view of how to smoothly pass complex elements such as workers, robots, parts, products, space, and time from upstream to downstream.

Follow Up After Install

Once the details of the system are established from start to finish, a risk assessment is conducted based on the basic design. Once the safety of the robot is confirmed, it goes into the manufacturing and programming of the robot system.

After the design drawing of the entire robot system is completed, it goes through manufacturing, testing, delivery, and installation, and then proceeds to the phase of production operation. But even with a successful deployment, the job of a robot manufacturer or system integrator isn’t over. The company has a long relationship with the end-users that use the system, including regular inspections, customer support, and assistance if failures occur. Kawasaki Heavy Industries has a dedicated call center to answer any questions end users have after installation. There is also a 24-hour help desk for problems that arise outside of business hours. Another reason for Kawasaki’s popularity among users is its extensive follow-up and customer service.

Kawasaki Heavy Industries’ after-sales service team was established more than 30 years ago. And in 1986, it established Kawasaki Robot Service Co., Ltd. (formerly Kawasaki Robotics, Ltd.), a company specializing in maintenance and after-sales service. Behind the Kawasaki robots, there is always a team of experts close to the robot’s life, from installation to operation, maintenance, and renewal.

There are many reasons why customers choose Kawasaki as a partner in the introduction of robot systems. One of the reasons for this is that, as a company that started as a manufacturer and has deep roots in this industry, it is fully equipped to support the introduction of robots to customers. For example, the Nishi-Kobe Plant has one of the largest robot showrooms in Japan. There are vertically articulated robots, parallel link robots, clean robots, and even duAro cobots and Successor systems. In the showroom, you will see work environments replicated for each robot type, such as welding, painting, and sorting lunch boxes on a production line.

Many users want to implement robots to help combat labor shortages. Or, they may want to increase production efficiency and diversify their product line. Another common reason is to prevent human error and improve product quality, or protect workers from harsh and dangerous work. Every company has its own incentive to think about robots. Industrial robots are certainly the best solution for these problems, but replacing humans and robots is not enough. There’s no such thing as a robot without a professional standing by and supporting from the beginning to the end. Automation systems can only run smoothly when they have both robot system integrators and robot manufacturers.

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Introducing Industrial Robots Faster!
Start of K-AddOn operation

Industrial robots cannot work by themselves. They need to connect to peripheral equipment such as grippers and vision systems so the whole system can work. In order to smoothly connect devices made by the various manufacturers, it is necessary to connect and link the respective software types. The K-AddOn platform was launched by Kawasaki to speed up the time it takes to connect the robot to its peripheral equipment and help ensure a smooth deployment. By opening the interface of industrial and collaborative robots made by Kawasaki Heavy Industries to peripheral equipment manufacturers, the robot system integrator and end-user can reduce the verification cost of equipment connection required at the time of installation.