Automation blog
EV transition made easy: Top three challenges to overcome in automotive manufacturing
23. november 2023 The transition to electric vehicles is a challenging path for automotive manufacturers. Long-established companies that have traditionally produced vehicles with combustion engines are now venturing into an entirely new realm of vehicle platforms. Let us investigate the top challenges facing the electric vehicle manufacturing industry and explore the latest innovative solutions on the horizon.
A meeting of minds: IT/OT convergence in industrial automation
22. september 2023 Future-focused manufacturers are edging closer to their ideals of flexible, efficient and sustainable production by exploring digital transformation in earnest. However, as interest in digitalisation builds, it is becoming apparent that a huge gulf exists between the worlds of OT (Operational Technology) and IT (Information Technology). And this divide needs to be bridged if today’s visions for factories of the future are to become tomorrow’s reality.But before we look at why a convergence of IT and OT is necessary and how this can be achieved, let’s take a step back to basics and clear up some misunderstandings around the terminology.
Empowering the workforce: OMRON's approach to skills development in European manufacturing
6. september 2023 Delving into OMRON's unwavering commitment to nurturing skills that empower the next generation, while the industry embarks on a transformative journey – a journey that unlocks the full potential of the Fourth Industrial Revolution (4IR) while boldly moving towards the Fifth Industrial Revolution (5IR).In the halls of academia, the boardrooms of visionary business leaders, and the chambers of forward-thinking politicians, a fervent debate evokes. It revolves around the profound shift from the Fourth Industrial Revolution, 4IR, or Industry 4.0 as it is also known, to Industry 5.0 will change the world in which we live.Historically the Industrial Revolution was the First Machine Age, and electricity the Second, then electronics was the Third, and the internet as platform the Fourth Machine Age. We are now entering the Fifth Machine Age, which highlights harmonious human-machine collaboration and the contributions of the industry to society. This is the moment to not only adapt but to lead, to pioneer, and to create a future where innovation knows no bounds. Klaus Schwab, the founder and executive chairman of the World Economic Forum has observed that: “We stand on the brink of a technological revolution that will fundamentally alter the way we live, work, and relate to one another. In its scale, scope, and complexity, the transformation will be unlike anything humankind has experienced before. Our world is undergoing a transformative shift. Global production is evolving, driven by the automation of traditional industrial practices through smart technology, M2M communication, and IoT integration. This synergy fuels heightened automation, seamless communication, and intelligent machines that autonomously analyse and diagnose challenges.The rise of AI sparks debates, hinting at deeper transformations within our societal tapestry. As we navigate this dynamic landscape, we are poised to embrace innovation and reshape our future.
Top 4 Ways to Tackle Labour Shortage with Automation
6. september 2023 Automation is a pathway to supporting manual workforce and not replacing them.Labour shortages in manufacturing are a growing cause of concern worldwide. While financial incentives and targeted workforce qualifications have been used as countermeasures, more innovative solutions are needed. Many manufacturers choose to automate repetitive activities but to what extent is it supporting the existing taskforce or is it taking away their jobs altogether?In 2023, Reuters disclosed an alarming trend: a record-high 53% of companies grapple with hiring difficulties. Staff shortages, soaring energy costs, combined with the pursuit of climate neutrality create new challenges. In the quest for sustainable manufacturing, innovative strategies to address labour gaps and enhance existing talent are the beacon of progress.Let us go over the top four ways to addressing the labour shortage and supporting the current workforce with automation:
From red lights to robots: OMRON celebrates 90 years of innovation
6. juni 2023 This year on Founder’s Day, OMRON looked back on 90 years of pushing technological boundaries, and looks forward to a future of automation innovation framed by sustainability, digitalisation and human-machine collaboration.May the 10th be with you… Every year, 10th May is probably the most important day in OMRON’s calendar. On this day, 30,000 OMRON employees around the world celebrate the life and legacy of the company’s founder, Kazuma Tateishi. They do this by recommitting to Tateishi’s vision of using technology to create a better world and by giving back to society - often by participating in volunteer and charity projects in their communities. Innovation Milestones OMRON's journey of innovation began in 1933 with the development of a high-precision timer for X-ray photography. This marked the company's first contribution to addressing societal needs. In 1960, OMRON unveiled the world's first non-contact proximity switch, revolutionizing advanced mass production capabilities. Since then, OMRON has continued to introduce groundbreaking technologies, including the first automatic traffic signal, unmanned train station system, wearable blood pressure controller, ultra-high-speed fuzzy logical controller, and automatic cancer cell diagnostic equipment.
Collaborative capabilities
31. mai 2023 Omron Automation robotics can be used in collaborative applications, where they work alongside human operators to pick up and place objects. The robots are designed to be safe to work around, with sensors and other safety features that prevent collisions and other accidents. This allows manufacturers to use collaborative robotics in a wide range of applications, improving productivity and efficiency while maintaining a safe work environment. With collaborative capabilities, manufacturers can take advantage of the benefits of automation while still maintaining a human touch in their production processes.
Buying or Leasing? How to finance your new cobot
26. april 2023 Food for thought for SMEs when funding automation projectsSkills shortages, digitization, sustainability, and energy-saving plans are accelerating automation projects in many companies. Once manual processes that lend themselves to automation have been identified, the next question that usually follows is: And what does it all cost?It can make sense to consider options such as leasing or robot-as-a-service. One example of tools that give small and medium-sized enterprises (SMEs) in particular a better overview the financial aspects of automation is the ROI calculator from OMRON. Anyone currently considering the purchase of a cobot or AMR can use this tool to reveal the return on investment.
Why automated inspection systems are critical for electric vehicle manufacturing
23. mars 2023 Safety trumps all other concerns in the automotive industry, and electric vehicle manufacturing is no exception. However, safety can also introduce complexity, and the complexity of today’s vehicles – particularly EVs – is such that manufacturers are no longer able to rely on traditional sample or audit-based inspection methods.
Can Artificial Intelligence (AI) in robot systems manage the functional safety parts?
20. mars 2023 Authors: Josep Plassa, Safety Product Marketing Manager at OMRON Europe and Atsushi Oshiro, Manager at the OMRON Development CenterRobots and AI systems have become an integral part of industrial manufacturing sites. To ensure the safety of workers while using robots, a detailed risk assessment is necessary. This assessment is carried out from the perspective of Functional Safety, which examines the five main elements employed by robots to determine autonomous control actions: Environment recognition, Action planning, Trajectory generation, Motion control, and Measurement.
How to speed up cobot integration
8. februar 2023 Good planning and strong partners help SMEs overcome hurdles in automation.Collaborative robots, also known as cobots, are enjoying great popularity because they make it possible to automate time-consuming and resource-intensive tasks. The global market for collaborative robots is currently estimated at around $1.2 billion. The sales volume of cobots reached a total of 32,300 units in 2021. Especially in times when it is becoming increasingly difficult for companies to find and retain suitable employees, such technologies are worth their weight in gold in many places. Speaking of gold, some may ask: Cobots must be extremely expensive, right? When does such an investment pay off?Automation expert OMRON would like to alleviate such worries, especially for small and medium-sized companies: Smart and integrated robotics solutions as well as cobots and mobile robots are feasible and affordable. For those who want to estimate the return on investment, OMRON’s ROI calculator provides a quick and easy overview.Cobots and autonomous mobile robots (AMR) are suitable for both SMEs and large-scale businesses. They perform tasks such as transport, palletizing, loading and unloading of machines, assembly, painting, or welding. They can be quickly and flexibly retooled and also programmed by non-experts. Material replenishment can be streamlined with AMRs, and machine and process loading with cobots. However, to successfully carry out such projects and accelerate robot integration, know-how and partners who are familiar with the subject matter are needed. And above all, employees must be informed and involved from the start of the project to be part of the change together.Here are some tips companies should keep in mind when integrating cobots:
Artificial Intelligence: don’t call me stupid
8. februar 2023 Ten years ago I was quite proud of how smart the machines in our own factory were. Now, with my today’s definition of smart, I realise they were actually quite stupid.Why? Because although they were doing what they were designed to do, the minute they encountered anything unexpected or out of the ordinary they were stumped. They resorted to asking the operator ‘what is wrong with me?’.Troubleshooting and getting machines back up and running called for smart people. Highly skilled operators. Experienced software and hardware engineers. The problem is that in the last ten years, these people have become increasingly unavailable. There quite simply isn’t enough new talent entering the industry to offset the number of workers reaching retirement age. When they leave the business, retirees take with them their hard-earned on-the-job knowledge that is a culmination of years of experience. With each departing worker, businesses are faced with the prospect of a less productive and less skilled workforce.
Top 5 automation predictions for 2023 from OMRON Europe
1. februar 2023 While a new year is upon us, with all its opportunities, I'd like to highlight some of the top trends that will impact and shape industrial automation in 2023 and beyond. The manufacturing industries will continue to face many challenges, and riding them out will involve building resilience and flexibility into business models. At the same time, companies must embrace emerging technologies - sensing, robotics, 5G and artificial intelligence - to help them solve the problems they face due to societal challenges.
Flexible, safe and easy collaborative welding solution from Guidetti Technology
20. august 2021 Guidetti Technology SRL has integrated OMRON collaborative robots (cobots) into its ‘EasyArc’ welding solution. This is used in collaborative applications on small batches of various types of metal carpentry
How labour shortages are affecting the logistics sector and why automation is the solution
11. august 2021 By Stuart Coulton, Regional Manager, OMRON UK North
Professional help for personal care: Putting a cobot to work
9. juli 2021 Of the many processes involved in finalising a consumer product, the final step can often be the most intricate. For this OMRON customer, the last step in production is to fasten the cover holding screw, closing up the unit—in this case, an electric shaver. Traditionally, the full process was completed manually, with an electric screwdriver in a multi-step process. This repetitive task is an ideal candidate for the help of an OMRON cobot.
Cobot boosts production by 15% at Topcustom
23. juni 2021 Topcustom srl, an Italian producer of custom-made bathroom sinks, has recently transformed part of its operations by deploying a collaborative robot (cobot) from OMRON. The new cobot is being used to automate all the finishing operations of Topcustom’s products made from Ocritech. This is a light material that is easy to work, guarantees perfect hygiene and has excellent resistance to UV rays.
Cisel ensures traceability, safety and quality by testing printed circuit boards with a cobot
17. juni 2021 Cisel is an Italian company that specialises in the design and production of flexible printed circuit boards (PCBs) for the automotive, civil engineering and manufacturing industries. The company recently chose an OMRON TM5 collaborative robot (cobot) to automate the electrical testing of boards used in the power steering system of a leading automotive manufacturer.
UV-C Robot helps businesses win the fight against Covid
16. juni 2021 As the UK’s customer-facing businesses plan their reopening strategies, keeping consumers and staff safe from Covid will be a key priority. In a bid to prevent future outbreaks at high footfall, everyday environments like supermarkets, bars and gyms, we have teamed up with UV Systems UK to produce an autonomous robotic sterilisation system that guarantees to kill the virus without damage or harm to surrounding goods.
Cobot ensures precise assembly of magnets for LITMAT’s drain plugs
3. juni 2021 Collaborative robots (cobots) are being used more and more extensively, in a range of different industries and across a wide variety of applications. They can make a significant difference to the efficiency and productivity of the production cycle. One company that is enjoying such benefits is LITMAT SpA.
Mobile robot transports waste for Kymenlaakso Central Hospital in Finland
7. april 2021 Waste transportation and logistics planning require a lot of work in hospital environments. Waste shipment is also a physical task that places demands on both time and human resources.
Choosing a robot for a smart factory
2. april 2021 Anyone planning to move towards a smart factory needs to choose carefully when considering possible robotic solutions. Should it be an industrial robot or a collaborative robot (cobot)? Autonomous mobile robot (AMR) technology or a fixed selective compliance assembly robot arm (SCARA)? The answer will depend on your specific needs.
Cobot Dashboard: How to visualize data for OEE improvement the smart way
16. mars 2021 The factory of the future is not only based on a well-orchestrated interaction of the most diverse machines, robots, sensors, and AI technologies. Entrepreneurs and decision-makers are also increasingly faced with the challenge of reconciling the vast amounts of data collected by the various production lines and making the best possible use of it to support their decisions. Not only does a comprehensive data strategy need to be developed. There are also technologies required that process and present the data in such a way that issues are immediately identified before major problems occur.
Automation for zero touch: Improving safety, quality and efficiency in F&B
15. mars 2021 Recent innovations in automation, robotics, image processing and artificial intelligence (AI) can help companies to migrate towards zero touch processes.
Productivity Peaks: Moving Maintenance From Preventive to Predictive
17. desember 2021 Maintenance is a vital key to a thriving business, especially in manufacturing where 24/7 plant equipment uptime is often expected as standard. As any established enterprise knows, keeping production lines and systems running optimally requires more than a skilled maintenance team. It also involves careful planning, tight scheduling, constant vigilance, a willingness to change out unworn parts, and a readiness to respond to unplanned events. At least, it used to.
Developing digital capability: how any factory can be smart
16. september 2021 Thankfully, the headline-grabbing ‘Industry 4.0’ isn’t reserved exclusively for the high-tech giants that span the globe, nor is the term ‘smart factory’ applied only to brand-new installations. In truth, any traditional factory can in principle take steps on the smart factory journey, by applying modularity to the existing installation.
Monitor machine stability with data science
16. juli 2021 Do you have a machine with no problems? You’re probably already collecting production and machine data, but not using it. With a quick scan of your data, it is possible to judge the usability and quality of the data and start using the value inside the data. This will help you define the first or next step towards a data enabled organization.
Cobot Dashboard: How to visualize data for OEE improvement the smart way
16. mars 2021 The factory of the future is not only based on a well-orchestrated interaction of the most diverse machines, robots, sensors, and AI technologies. Entrepreneurs and decision-makers are also increasingly faced with the challenge of reconciling the vast amounts of data collected by the various production lines and making the best possible use of it to support their decisions. Not only does a comprehensive data strategy need to be developed. There are also technologies required that process and present the data in such a way that issues are immediately identified before major problems occur.
Developing smart and flexible production: Norwegian university sets up new manufacturing lab packed with robots
10. februar 2021 The Norwegian University of Science and Technology (NTNU) has developed a new educational laboratory in Ålesund to facilitate learning and extend the implementation of automation and robotics amongst manufacturers in the region. The lab is packed with a wide range of OMRON solutions – both hardware and software.
Data paradise factory floor: get more out of your machine and production information
25. september 2020 Strategic Data Science is an essential pillar of every Industry 4.0 scenario. A four-step data mining approach based on CRISP-DM supports successful projects.
Get the full value from your factory floor data with data sciences
19. juni 2020 Industry 4.0 and IIoT have been buzz words for several years and these concepts are actually implemented on more and more machines. A huge amount of data becomes available: machine data, data of the production process and data regarding the manufactured product. Big Data has entered the factory floor.
High-speed robot tests the reliability of black boxes
14. mai 2020 A non-destructive alternative to crash tests
Integrated data control, motion control and machine vision for next-generation automotive production line
24. april 2020 The Mexican regional headquarters of a leading manufacturer of premium air brake actuators for global on-highway and specialty markets required a new automated production assembly line. One of the company’s key performance indicators is to deliver a fully assembled product every 30 seconds, and it is with this end goal at the forefront that the team started the process of automating the production line.
IoT security for manufacturers
11. desember 2019 The Internet of Things (IoT) is a recent concept, involving the connection of devices that incorporate electronics, software or sensors, with the aim of collecting and exchanging data.
Smart machines: laying the golden egg?
16. oktober 2019 Greater manufacturing efficiency: it’s the golden egg we’re all looking for. But it’s getting increasingly hard to find. The solution could be smarter automation, which involves lots and lots of data (‘big data’) and data collection and data-driven modelling. The smart machine then uses the models to automatically adjust its own behaviour (i.e. machine learning).
A practical illustration of IoT and Industry 4.0
1. oktober 2019 The Internet of Things (IoT) is a relatively new phenomenon. Prof Dr Thomas Pospiech, a teacher of Production and Process Management at Heilbronn University of Applied Sciences, was interviewed recently about the ‘IoT box’ he’s developed to give his students a practical illustration of this fairly abstract concept.
Factory automation: four tips for the future of food & beverage manufacturing
16. juli 2020 The coronavirus pandemic has posed major challenges to organisations of all types and sizes. In the food and commodity industry, companies have faced significantly reduced consumption and disrupted supply chains, while at-home consumption increased, and out-of-home consumption came near to a standstill. But how can manufacturers adapt their business strategies and production processes both now and in the longer term? The pandemic may provide an opportunity for rethinking outdated processes and procedures and enhancing them with concepts such as innovative robotics, sensor technology and holistic automation strategies.
Improve OEE with Artificial Intelligence at the Edge in Food Manufacturing
16. oktober 2019 Implementation of Artificial Intelligence (AI) in food manufacturing is picking up speed. Many F&B companies are realizing that AI presents an opportunity to increase not only the Overall Equipment Effectiveness (OEE) – and therefore combine reduced costs with increased productivity – but also to improve the analysis of data to support continuous improvement programs such as reducing waste or process operations variability.
3 Steps to Optimize Operational Efficiency for the Future of Manufacturing
2. oktober 2019 Operational Excellence is required to maximize capital expenditures. But at the same time manufacturers are challenged to move away from traditional high volume, low mix production runs, to more complex high mix, low volume production with consumer demand linked directly with production. How to optimize operational efficiency to be ready for the future of manufacturing?
The power of collaboration between machines, people and teams
1. oktober 2019 With today’s rapid advances in technology, the manufacturing sector needs to be increasingly agile, ready to adapt to changing demands. Production lines must be more flexible, so that they can cope with shorter production runs, more varied products and tight deadlines. So how can manufacturers address these challenges? The solution lies in more advanced, interconnected and intelligent systems that can be programmed to handle a range of tasks.
Minimum complexity, Maximum yield
8. juli 2019 Omron's leading position in packaging automation in the Food & Beverage industry is based on smart and simple solutions that result in solid success. A concept that we dubbed Perfect Packaging. Omron's Perfect Packaging approach structurally eliminates risks and boosts production even in tough situations when high throughput is required. But also optimises your filling. Minimising under- or overfill.
At Omron we serve to protect Package Integrity!
8. juli 2019 Protecting a product is the main purpose of any package. Food packaging that is not closed completely airtight can cause a whole range of problems resulting in huge expenses and problematic long-term consequences for manufacturers. Loss of nutrients and aroma to premature spoilage are the least problematic relative to the costly aftermath that easily comes around the corner when consumer health is at stake and recalls enter the media.
Perfect Packaging, ordinary packaging executed extraordinary well
8. juli 2019 Packaging processes rarely harbour extremely surprising variables. From manufacturers to system integrators, machine builders and industrial automation providers, we all know the essentials that make packaging production a definite success. However, the everyday reality on the factory floor is that small imperfections in the process result in major output disturbances. That is why Omron introduces its Perfect Packaging concept featuring smart innovations that ensure that ordinary F&B-packaging is executed extraordinary well. We help make your bottom-line top!
Go with the Adaptive and Dynamic production flow!
6. mai 2019 Flexible and fast responses to changes in market dynamics improve performance. Made-for-me production flows are the future of manufacturing coherent with Industry 4.0. A reality that Omron already provides today through its cutting edge innovative-Automation approach. Turning factory floor data into highly valuable information, we realize intelligent automation solutions for manufacturers around the globe.
Smart sensing for multiple materials!
6. mai 2019 You know the routine. Switching from one product to another on your production line means a costly full stop, making all kinds of changes, starting up again, discarding the materials and packaging already fed into the line together with start-up rejects, and only then can production resume. Well, have we got good news for you: smart sensing for multiple materials!
Rock solid results with flexible production & robotics!
6. mai 2019 Today's market requires an increasingly agile production environment. Traditional industrial automation and robots are often too inflexible to successfully accomplish mass customization. Omron is enabling smart Industry 4.0 scenarios with a rare combination of intelligent automation solutions and robotics. Perfecting seamless human-robot collaboration and making more and more use of AI-driven possibilities, we assist manufacturers in realizing rock solid results with flexible production and robotics.
Direct link IT & OT puts factories on cloud nine
25. februar 2019 Just imagine getting rid of cumbersome middleware or PC data concentrators at your production locations and being able to enjoy the benefits of direct database connectivity. Where Information Technology (IT) & Operational Technology (OT) come together something beautiful happens. We have created a production environment in which databases and machine controllers are best friends and keep in touch continuously.
Don't let vibrations catch you off balance!
25. februar 2019 Machine operators are aware that sudden increases in vibrations or noise variations can herald a serious shake-up on their production lines. Unfortunately, it is hard for humans to quickly notice the indicators of, for instance, out-of-balance mechanics. The human touch is no match for dedicated sensors combined with high-speed Analogue Input Units that can reliably, precisely, and easily acquire synchronized data.
Integrated data control, motion control and machine vision for next-generation automotive production line
24. april 2020 The Mexican regional headquarters of a leading manufacturer of premium air brake actuators for global on-highway and specialty markets required a new automated production assembly line. One of the company’s key performance indicators is to deliver a fully assembled product every 30 seconds, and it is with this end goal at the forefront that the team started the process of automating the production line.
ŠKODA AUTO uses LD mobile robot at Vrchlabí plant
17. mars 2020 The autonomous robot contributes to the continuous improvement of work safety in Vrchlabí and helps to minimise work risks. It recognises people crossing its path as well as other vehicles and stationary obstacles.
Green is key: sustainability in battery manufacturing for E-mobility
5. februar 2020 Today, sustainability is no longer a niche topic, but something that companies are integrating into their business strategies. Not only are sustainability practices necessary to answer the changing demands of consumers, the marketplace and governments, they are also increasingly being seen as a competitive strength. That’s because sustainability practices reduce energy consumption and waste, and also help companies use their resources more efficiently. They even help companies optimize their manufacturing agility and enable them to respond to fluctuating demand and the growing need for personalization. And finally, sustainability can play an important role in acquiring and retaining customers, as well in developing new market opportunities.
Agile and clever tailor-made mobile robotics
4. november 2019 Major German automotive group optimizes efficiency and innovation leadership in material handling with Omron LD mobile robots and a conveyor attachment from cts GmbH.Automobile production and assembly line production have always been closely linked. It was not until Henry Ford began using conveyor belts in his factories in 1913 that the car was able to conquer the world as a mass-produced product. Today, a working day without assembly lines is inconceivable at the BMW factories. The group relies on innovative transport and logistics to increase efficiency and flexibility, to better link work processes, as well as to relieve employees from repetitive and time-consuming tasks. These concepts include Omron LD mobile robots for material transport that deliver a particularly high return on investment (ROI). These autonomous mobile robots are equipped with a conveyor tower - a height-adjustable load handling device, developed by system integrator cts GmbH. The interaction between employees and transport robots at BMW impressively demonstrates how factory harmony can be implemented in the factory of the future.