Collaborative robots increase productivity by 90%

Carl Zeiss India

In short

In 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) installed a UR5 cobot, which boosted the company’s machining utilization. A single cobot arm now tends three metrology machines in the same cycle.

The business transformation

Carl 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.

Carl Zeiss India

Industry Metal and Machining
Country Asia
Number of Employees 5-25
Cobots used UR5
Video — Carl Zeiss India , India

The solution

The UR5 gave Carl Zeiss India the flexibility to integrate three machines with a single cobot

The integration resulted 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.

The products

The products

Carl 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).

Carl Zeiss India

We had a productivity of 50% with an operator. But now, when integrating this system with a cobot, you can expect more than 90% utilization of the each machine. This gives a neat and flexible system which can be adapted in just a day or two for a new system. . I think this is where we have to be looking at cobots being applied to automation. The future is great with cobots! Even while looking at 24x7 productivity, the only solution is with cobots.

Ravikumar Sirige, Division Manager, Industrial Quality Solutions, Carl Zeiss India (Bangalore) Pvt. Ltd.
Integrating three machines with a single UR5 at Zeiss Metrology Centre, Bangalore, IndiaQuality inspection with the UR5 at Zeiss Metrology Centre, Bangalore, IndiaNo fencing required with cobots at Zeiss Metrology Centre, BangaloreUR5 used to Pick & Place at Zeiss Metrology Centre, Bangalore

Automation challenges solved

  • Operational space and safety of manual loading systems
  • Changing production lines with manual loading systems
  • Low productivity rate of 50%

Key value drivers

  • 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

Tasks solved by collaborative robots

  • Quality inspection
  • Pick & Place
  • Lab Analysis & Testing

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