In 2023, robots are faster, cheaper, and more sophisticated than ever before. They are easily programmed, customizable, capable of performing tasks autonomously, and can work in close proximity to their human counterparts without compromising safety.
These factors combined have seen the rise of mass customization on our factory floors. What are some of the benefits of this production model and how can industrial businesses set themselves up for success?
What Is Mass Customization?
Mass customization, also known as made-to-order or built-to-order, is defined as "a marketing and manufacturing technique which combines the flexibility and personalization of custom-made products with the low-unit costs associated with mass production.”
Put simply, it enables industrial businesses to produce a customized product with the same ease, efficiency, and cost as a mass-produced one. Today, mass customization is used to produce everything from one-of-a-kind furniture pieces and customizable shoes, to personalized clothing and tailor-made computer software.
The benefits of mass customization include:
- A higher return-on-investment (ROI) and better profits, because manufacturers can charge more for their products.
- Improved customer satisfaction because customers can choose their favorite styles, colors, and designs. Not only does this reduce customer turnover but it also will attract new customers to a business.
- Increased product quality, because items are made to suit the requirements of the individual.
- More effective inventory management because customized products are typically made to order.
The robots of today also are enabling mass customization by assuming the most repetitive and time-consuming tasks on a production line. This allows human workers to focus on the creative, detail-oriented, and value-adding components that typically qualify a product as one-of-a-kind.
Advances in robotics also support modular cell production, which describes the process of subdividing a production line into smaller sections, called modules, which can be independently created and applied to different systems. Within these modules, collaborative robots (cobots) and human employees often work side–by-side.
This versatile manufacturing method lends itself well to mass customization because assembly time is minimized and specific components within each module can be quickly switched in and out. In addition, once a module is established and proven to be effective, it can be quickly replicated to increase production.
The ease with which factory robots can be customized is another reason that mass customization is on the rise.
How to Customize Your Factory Robots for Mass Customization
If you’re looking to customize your factory robots to better enable mass customization, ask yourself the following questions:
1. What Are You Hoping to Achieve?
Whether you’re interested in mass customization or not, know what you hope to achieve before investing in new factory robots. For example, are you hoping to drive efficiencies, increase production, improve employee safety, or grow your customer base?
2. What Add-Ons Will Your Robot Require?
Today’s industrial robots have far-reaching applications. A robot arm, for example, may well be a worthwhile investment. But it is the additional components you acquire that will determine whether the robot arm grips, picks, sorts, welds, polishes, packs, labels, inspects, or assembles.
Once you’ve purchased your welding torches and your grippers, consider the need for additional sensors and vision systems, which can quickly enhance your robot’s capabilities and output.
3. Where Will the Robot Live?
Can the robot stand by itself or will it need to be bolted to the floor or wall? Are additional mechanisms and safeguards required to keep it in place and protect your workers? If so, where will it live?
While cobots are designed to work in the same vicinity as humans, even these machines might need securing in place; make sure you have the means to do so.
4. What Software Will Your Robot Need?
Factory robots arrive with pre-installed software, but you will be required to write the program that instructs them to perform specific tasks. You may also choose to purchase and install additional applications that better meet the needs of your business.
5. Do You Need External System Integrators to Set Up Your Robot?
You may well end up purchasing different components for your robot from various suppliers. The supplier of a robot arm, for example, might offer certain add-ons, but they won’t address every possible application for the machine or every one of your requirements.
If you do decide to buy your software from one place and your pickers from another, you’ll need a qualified team of system integrators on hand to help you put it all together. If you don’t have the existing resources to take this on, you can outsource to contractors.
6. Who Will Be Operating Your Robot?
Who will be responsible for operating and monitoring your factory robots? You may need to provide your employees with additional training to guarantee a good ROI.
