Opportunities and Challenges of Collaborative Robotics in a Human-Centric Automobile Assembly Process

Abstract

Mass customization and complex products have challenged the automobile industry in terms of quality, process capability, and efficiency. This evolution has made automotive assembly process a highly complex and human-centric. Compared to other shops in automobile manu-facturing, assembly shop requires human skills such as cognitive decision making, dexterity, and adaptability as the product complexity is at its peak in that part of the process.

A Human-Robot Collaborative System (HRCS) provides a framework through which automation can be increased in automobile assembly domain. Simultaneously, productivity and quality performance can be improved with human-robot collaboration. A collaborative robot (commonly referred to as a cobot) is an integral part of the human-robot collaborative system. As a technology, it offers enhanced capabilities in efficiency and quality. It also promotes improved safety and ergonomics through inherent safety features. However, due to its reduced size and limited capabilities, especially in reach and payload, its applicability is not straight forward.

This study examined the opportunities and challenges of cobots in a human-centric automotive assembly line using qualitative methods through a literature review and an empirically study exploiting the Task-Technology-Fit (TTF) approach. The empirical part included a six-step approach to assess cobot capabilities with assembly task characteristics, identifying potential applications. Additionally, the study evaluated the characteristics of cobots and compared them to conventional industrial robots through expert interviews. Finally, the utilization evaluation for cobots were assessed based on the combination of findings in literature review and empirical study. The research was conducted at a Finnish automotive company, focusing on a single product and a low-volume assembly line.

As a result, the biggest opportunities for cobots can be found from operating collaboratively with humans at the same workstation without the need for external safety measures. According to the study, the feasible activities for collaborative robots include fastening operations, quality inspections, and lifting and moving parts. Despite their safety capabilities, convenient exploitation and mobilization, cobots tend to lose their competitive advantage if external safety measures are required, as lightweight industrial robots can perform collaborative processes with external safety measures while offering better payload capacity and more cost-effective system