Collaborative Robots increase Productivity by 90%, Delivering 24x7 Manufacturing Capability at Carl Zeiss India
01 The short storyIn an effort to solve the issues created by changing production lines with manual loading systems, the ZEISS Metrology Centre, part of Carl Zeiss India (Bangalore) Pvt. Ltd., installed a UR5 cobot, which increased the company’s machining utilization by over 90% and gave it the ability to manufacture 24x7. A single cobot arm now tends three metrology machines in the same cycle.
02 The challengeCarl Zeiss India Metrology Tech Centre in Bangalore used to have cumbersome manual loading systems that were problematic and inflexible when changing production lines, creating many operational problems.. Their use was also limited to the presence of staff. A total of 15-20 employees make up the Metrology Tech Centre in Bangalore, with only one operator who could operate a single machine at a time, thereby limiting productivity. Carl Zeiss India realized they needed to automate repetitive production tasks in a seamless manner with an agile, automation solution that would enable them to manufacture around the clock.
Video — Carl Zeiss India , India
03 The solution
The UR5 gave Carl Zeiss India the flexibility to integrate three machines with a single cobot, resulting in increased productivity, which skyrocketed from 50% to over 90%. The cobot also allowed for adaptability through seamless, problem-free switches in productions line that can be easily done in a day or two, making 24x7 operations a reality.
A single UR5 integrates three metrology technologies: CMM, contour machine, and a non-contact measuring machine. The cobot scans the barcode of every component and places it in each of these machines to be checked according to the relevant program. After the inspection, the measuring machine sends the information to the cobot regarding whether or not the component is fit for use. The cobot, in turn, sorts the part accordingly, either placing it in the ‘’Okay’’ or the ‘’Not Okay’’ bin.
04 The productsCarl Zeiss India Metrology Tech Centre has been around for 40 years in India, and is a recognized provider of automated Industrial Quality Solutions, manufacturing coordinate measuring machines (CMMs). https://www.zeiss.co.in/
Integrating three machines with a single UR5 at Zeiss Metrology Centre, Bangalore, India
Human Robot Collaboration and easy programming with the UR5 at Zeiss Metrology Centre, Bangalore, India
Quality inspection with the UR5 at Zeiss Metrology Centre, Bangalore, India
No fencing required with cobots at Zeiss Metrology Centre, Bangalore
UR5 used to Pick & Place at Zeiss Metrology Centre, Bangalore
- Operational space and safety of manual loading systems
- Changing production lines with manual loading systems
- Low productivity rate of 50%
- Flexible and space-saving, with no fencing requirements
- Elimination of problems arising from cumbersome traditional loading systems
- Integrates three machines with a single cobot
- Maximizes rate of productivity
- Quality inspection
- Pick & Place
- Lab Analysis & Testing
Are you ready to automate your business?
Cost-effective, safe and flexible collaborative robots - or cobots- are making automation easier than ever, even for the small and mid-sizes companies.