Introducing robotics to existing manufacturing line

---

Our client, a leading supplier of high-quality paint brushes and other paint applicator products, sought to modernize their manufacturing process while maintaining a strong commitment to their workforce. With increasing production demands and the need for precision in brush assembly, the client wanted to explore robotics as a solution without creating apprehension among employees about job security.

1. Manual Labor Bottlenecks:
   • High dependency on manual assembly slowed production during peak periods.
   • Workers faced repetitive tasks leading to fatigue and potential for error.

        2.  Workforce Concerns:

• Employees were apprehensive about robotics, fearing job displacement.

        3.  Limited Technological Experience:

• The company lacked prior experience with automation and robotics, making integration a steep learning curve.

Our consulting team partnered with the client to deliver a strategy that addressed both technical and human factors for successful integration. The approach included:

Workforce Engagement and Education:

• Conducted employee workshops to demystify robotics, explaining their role in complementing human efforts rather than replacing them.
• Shared case studies and facilitated Q&A sessions to address concerns directly and transparently.

Operational Assessment:

• Analyzed the current production line to identify bottlenecks and areas where collaborative robots (cobots) could deliver the most value.
• Focused on repetitive, low-skill tasks to free up workers for higher-value responsibilities.

Custom Integration Plan:

• Recommended a cobot specifically designed for precision and safety in human-centric environments.
• Developed a phased deployment plan to gradually integrate the cobot while minimizing disruptions.

Training and Upskilling:

• Designed training programs to equip employees with skills to operate, troubleshoot, and collaborate with the cobot.
• Highlighted new roles emerging from automation, such as cobot programming and maintenance.

1. Initial Pilot Deployment:
   • Integrated the cobot into a single production cell to test its impact and gather feedback from employees.
   • Monitored performance metrics, including production speed, accuracy, and employee acceptance.

         2.  Full-Scale Integration:

• Expanded the cobot’s role across the manufacturing line after refining processes based on pilot results.
• Ensured seamless collaboration between human workers and the cobot.

          3.  Workforce Empowerment:

• Conducted ongoing training sessions to reinforce the value of robotics and build confidence in new roles.
• Created open forums for employees to share feedback and voice concerns.

Enhanced Productivity:

• The cobot increased assembly line efficiency by 35%, meeting rising production demands.

Improved Workforce Engagement:

• Employee surveys showed a 75% increase in confidence regarding robotics after the education program.
• Workers transitioned into higher-skilled roles, enhancing job satisfaction and career prospects.

Error Reduction:

• Precision tasks performed by the cobot reduced assembly defects by 20%.

Sustained Growth:

• The company experienced a 15% reduction in operational costs within six months of integration, enabling reinvestment in workforce development.

By focusing on both the technical and human aspects of automation, our consulting team enabled the client to modernize their operations while fostering a positive, collaborative environment. The project demonstrated that thoughtful integration of robotics can boost efficiency and create opportunities for workforce growth, dispelling fears of job loss and ensuring a harmonious transition into Industry 4.0.