Robots have presented a new dimension for the reduction of workers compensation costs.   While no robot will ever have human dexterity or sensory ability, robot arms today with their computer controls and continuous path motions have been able to be programmed to duplicate approximately 100 of the 1500+ hand motions required to successfully work in many complex manufacturing systems.  As robotic integrators and users gain more practical robotic experience, software, simulation and other advancements in system and processing will evolve.  This evolution in technology will provide users with further cost effective solutions to many finishing applications.

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Job Smart System integrates Technology Advances

Computerized simulation of robotic applications has been used for years to evaluate potential applications for reach, tool design and cycle time.  Expanded robotic applications are no different as the range of industries increases from manufacturing to service.  Simulation methods have been successfully used to establish equipment arrangement, evaluate design and estimate cycle times. Robotics designers know how to do this very well.

The greatest expanded benefit of using the Job Smart System to define human factors simulations will be to reduce the amount of development range of motion requirements and process teach time.  Being able to establish the biomechanical job demands for example, the lift, carry and place functions of a material handler allows engineering process points to be done during development and test off-line. This frees work pods in any industry from interrupting production.  Field experience has proven that the best data for robotic development is to simulate the human body with an off-line taught program. Using the job smart systems competency based analyses of job demands (validated with ergonomic analysis) can launch a new line into production with a 20% savings of time.

Justification Factors
when surveying any organization for robotic potential, one must take into consideration a number of factors that could help or hinder the justification of the application.  Some factors to consider include the following:

Labor Cost

• What is your direct cost of labor; how many workers are there on each shift? 
• What is their hourly rate and benefit cost?
• Many shops run only single shift operations. It is very difficult to cost justify any type of automation on a single shift basis.

Workmen's Compensation Cost

• Are ergonomic analysis factors indicating there a chance of back injury?  
• Are the job demands requiring repetitive hand motions to process, adding to the potential of ‘‘Carpal Tunnel Syndrome’‘?  
• Is the environment noisy, and/or dirty, contributing to health risk factors?
• Is the work tedious or boring leading to worker apathy and safety problems?  

 Workmen's Compensation Claims are on the rise.  Manufacturing Example: The manual processing of both small and large parts could be a significant factor in future rising benefit cost.  An automated robotic finishing cell could greatly minimize this type of exposure by removing the operator from the health risk associated with the tedious, dirty and noisy environment of manual finishing.

Governmental Regulations

• Will the worker operated or manual equipment meet OSHA standards?  
• Will future air quality requirements allow open area finishing?
• Will disposal of debris (hazardous material) continue to increase as a problem?

Just-In-Time Manufacturing

• What are your corporate goals regarding product inventory?   
• Will your product mix expand or reduce in the future?  
• Will your competition require you to reduce product cost and improve delivery to stay competitive?

Quality Control

• Will the demands of the consumer require the improvements in quality only automation can provide?

Available Work Force

• What is the availability of workers in your region? 
• If you need to expand production, can you hire and train the required work force in an ample time?  
• Does your department by department analysis show continuous improvement of control of your quality and productivity?  
• Do work rules affect your ability to respond to market conditions?  
• Will the elimination of risky range of motions (hand finishing) improve your overall competitiveness in your market?
• In many plants, any finishing department controls the productivity and quality of the finished goods, safety is often second fiddle to the “out the door “mentality. To increase production capacity, will your labor market support the hiring needs you have?
• With training, how many employees will last even one year on the job?

Perishable Cost

• Will robots reduce your costs of any media
• Will robots reduce your costs of personal protective equipment ( gloves , glasses , and hearing protection ( hearing conservation program) can cost a low average of $ 500 per year per worker
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•  Safety Equipment
  Operator gloves, aprons, earplugs, leg and shin protectors, and safety glasses are all items most companies provide to their worker to meet OSHA and local safety codes.   A typical worker can use two pairs of gloves a shift and one pair of safety glasses a week.  This could easily account for $2,000.00 or more of indirect cost per worker per station a year.  The robot, of course, does not require any of the above safety items.  

Job Smart project analysis summaries

Job Smart System can provide an analysis of

What components should comprise a robotic system?

How the pieces fit together

And how job demands can be enhanced to reduce the risk of illness and injury on the job.

Job Smart System can determine what factors influence cost, and guidelines to help potential users conduct an in-house survey of existing applications. Job Smart System can specifically develop simulation examples to help determine the system requirements to successfully implement a robotic solution 

Job Smart System can help you evolve from automated applications to SMARTBOTS