Development of Production System and Robotic Manufacturing.

Development of Production
System and Robotic Manufacturing
Rethinking manufacturing and consumption,
Japanese perspective
Bio-Robotics and Human-Mechatronics Laboratory
Graduate School of Information, Production and Systems, Waseda University
http://www.waseda.jp/sem-matsumaru/
Takafumi MATSUMARU
http://www.f.waseda.jp/matsumaru/
matsumaru@waseda.jp
Graduate School of Information, Production and Systems (IPS), Waseda University
2019.09, VIU Graduate Seminar. Rethinking manufacturing, consumption and globalization in the era of automation

Outline
 Production system
 Mass production
 Multi-product variable-volume manufacturing
 Mixed-flow production, Variable-product variable-quantity manufacturing
 Cellular manufacturing system
 One-worker stand/booth/shop type
 Robotic cellular manufacturing
 Human-robot coordination type
 Key technology
 Dual arm
 Collaborative robot, Co-bot
 Our research project
 Purpose, Subject
 Human-robot relationships while working
 Sharing
 Coordination
 Cooperation
Bio-robotics & Human-mechatronics Lab., Grad School of IPS, Waseda Univ., Japan Spt. 2019 2

Production system
 Production system
1. Mass production.
 Producing large amount of standardized products, especially lines
as flow production or continuous production.
2. Multi-product variable-volume manufacturing.
 A variety kinds of products in different amount of quantity are
produced in the same production system.
3. Mixed-flow production line.
 Small-quantity products in similar production method are collected
to maintain the amount of production for the effects of mass
production.
4. Variable-product variable-quantity manufacturing.
 Flexible production changing variety and quantity of products.
5. Cellular manufacturing.
 A worker taking charge of multiple operation processes.

1) Mass production
 Mass production.
 Producing large amount of standardized products, especially lines
as flow production or continuous production.
 Popularized in 1920s with Ford Motor Company.
 Purpose)
1. To increase productivity, decreasing losses on switching
production facilities such as setup time.
2. To utilize low-paid workers for each simplified process after
subdividing the manufacturing process.
3. Mass production in constant quality, without depending on
workers' skill.
 Feature)
1. Standardization of product.
2. Normalization of parts.
3. Segmentation of manufacturing processes (assembly-line
operation) --- adopting conveyor system, without skilled worker.

2) Multi-product variable-volume manufacturing
 Multi-product variable-volume manufacturing.
 A variety kinds of products in different amount of quantity produced
in the same production system.
 Advantage)
1. Offering product based on customer profiles:
 Development and providing the product with quality, function, and design
tailored to customer needs.
2. Reducing risk of large stock of products:
 Adjusting the number of products, based on customer needs, considering
trends in market demand, only when receiving the order, etc.
 Disadvantage)
1. Decreasing productivity (by some chance):
 With increasing the number of switching for the product with different materials
or production method.
2. Increasing in cost:
 Due to development of variety of products, increasing management man-
hours, frequent set-up change for different products.

3) Mixed-flow production.
4) Variable-product variable-quantity manufacturing.
 Mixed-flow production.
 Small-quantity products in similar production method collected to
maintain the amount of production for the effects of mass
production.
 Standard configuration of production line is constructed, and the
process difference corresponding to each product is built into.
 Remarks)
1. Standardization of products and parts, strongly taking aware of
manufacturing in standard line even at the time of design stage.
2. Highly-flexible production line to absorb the differences in
processes.
3. Production management, such as factory operation rate, line
balance, set-up time, and so on.
 Variable-product variable-quantity manufacturing.
 Flexible production, changing variety and quantity of products.

5) Cellular manufacturing system
 Cellular manufacturing system.
 Single-worker stand/booth/shop type.
 Single or a few workers --- assembling or inspection.
 Multiple different machines in U- or L-shaped configuration.
 Single worker takes wide range without moving much.
 Popular in 1990s, as a fundamental in JIT (just-in-time).

 Cellular manufacturing system. (cont.)
 Advantage) Improvement of productivity and quality.
1. Highly-mixed, low-volume production.
 Responding to diversification of customer needs.
2. Timely supply of products.
 by adjusting number of cells and workers.
3. Production lead time shorter.
 Not affected by other processes.
 Each cell works individually.
4. Inventory (finished good, in-process, parts) reduction.
 Reduction of working capital, improvement of cash-flow.
5. To increase workers' motivation: responsibility to consistently
handle until finished, with sense of accomplishment.
 Voluntary improvement of product quality and work efficiency
 Utilizing the ability of multi-skilled workers in Japan with
technological strength and high level of awareness.

 Disadvantage)
1. Securing and training of versatile (multi-skilled) workers.
 difficult by contractors and non-regular employees.
2. Workload of a worker.
3. Not suitable for processing (but for assembling and inspection).
4. Depending on individual worker's skill.
 Waiting for process = waste of time.
5. Unstable working speed.
 depending on individual skill, motivation, health condition, etc. making slippage
(between budget and actual results).
Cellular Manufacturing What It Is
And Why It Matters [2016.06]
(02:31)

 Subject) Improvement of productivity and work efficiency.
1. Parts supply to the cell.
 Difficult to synchronize the cell production and parts supply.
 Strengthening of partnership with parts suppliers.
 Neighboring locations of the cell production and parts manufacturing.
2. Clarification of responsibility of multiple workers, relation with
workers around the cell, and instruction method to them.
 Standardization of work quality.
 decreasing the operational errors.
 Standardization of production time.
 keeping the work pace.
 Preparation of on-line manuals, such as usage of parts box.
 corresponding the assembly task instruction with the used parts instruction.
 preventing neglects and mistakes.
3. Improvement activities in the whole factory.
 Keeping parts, tools, and facilities tidy and in order.
Standardization and optimization of maintenance activities.
 5S activity: Sort (Seiri), Set in order (Seiton), Shine/Sweep (Seiso), Standardize
(Seiketsu), Sustain/Self-discipline (Shitsuke).

5S activity
 5S activity
 A workplace organization method that uses a list of five
Japanese words.
 Sort [Seiri], Set in order [Seiton], Shine/Sweep [Seiso],
Standardize [Seiketsu], Sustain/Self-discipline [Shitsuke].
Toyota Material Handling Why 5S
[2016.05] (02:35)

Cellular manufacturing system
 Cellular manufacturing system
1. Single-worker stand/booth/shop type.
 Single or a few workers --- assembling or inspection.
2. Robotic cellular manufacturing type.
 Automated production.
3. Human-robot coordination type.
 Combined cell of automated operation by robot and manual
operation by worker.
Integration of technological labor (robot) and skilled labor (human).

2) Robotic cellular manufacturing type
 Robotic cellular manufacturing type.
Robotic automated cell.
Robotic production cell.
 Compact and flexible automated
production equipment.
 Small robot.
 End-effector (robot hand).
 Sensor (vision, tactile, force, etc.).
 Controller (interference avoidance,
cooperative control).
 Key technology)
 Modularization.
 Standardizing and generalizing various functional
modules (robot module, jig module, parts supply
module, HMI module, specialized operation
module, etc.).
 Cost reduction.

2) Robotic cellular manufacturing type
 Robotic cellular manufacturing type.
 Subject)
1. Multiple tasks by a single robot.
 Reducing the number of hands and jigs
(for equipment cost, cycle time, etc.).
 Making it intelligent by using various
sensors, such as force/torque sensor and
2D/3D vision sensor.
2. Difficult teaching and programming.
 Providing various tools and functions, such
as interactive programming, 3D
simulation, machine learning function for
movement optimization, intelligent
teaching with sensory data, etc. to assist
launching the cellular production and
shorten the programming time.
Okuma Fully Automated
Production Cell [2016.11] (03:50)

3) Human-robot coordination type
 Human-robot coordination type.
 Integration of technological labor (robot) and
skilled labor (human).
 Example)
 Coordinated assembling system.
 Mobile robot --- preparation.
 Parts placing and supporting by mobility and dual-arm
 Information provided through LCD and Laser pointer.
 Human worker --- assembling.
 Task information presentation method.
 Safety technique.
 Cosmetic plant.
--- coordinated operations in a cell.
 Dual-arm robot --- printing and labeling.
 Human worker --- visual examination with one's
sensitivity.
Collaborative Robot -YuMi at ABB
Elektro-Praga - [2016.07] (02:33)

Key-tech 1) Dual-arm robot
 Dual-arm robot.
 Human-like two arms
 Operated dexterously, work repeatedly, accurately and delicately.
 Aiming at multi-skilled worker.
 Developed and commercialized one after another.
Yaskawa, Motoman-
SDA5D/5F (2009)
Kawada, Nextage
(2011)
Rethink Robotics,
Baxter (2012)
ABB, YuMi (2015)

 Dual-arm robot.
Yaskawa Motoman SDA10 Robot
Assembly Video [2013.04] (02:13)
Nextage
Industrial
Humanoid Works
Alongside People
#DigInfo [2011.11]
(03:21)
How Baxter Robot Works
[2012.09] (03:23)
YuMi at Hannover Fair 2015
Overview - ABB Robotics
[2015.04] (02:02)
Rise of the
Robots - hi-tech
[2013.06] (02:06)

 Dual-arm robot.
 Feature)
1. Sensitive and complex movements.
 Using redundant DoF (degree of freedom), force/torque sensor, image
processing, etc.
2. Reliable (safe and secure) operation by dual arms.
 e.g.) Actual work by one arm, and supporting work by the other arm like
supporting a work-piece.
3. Multiple tasks simultaneously.
 e.g.) One arm releasing a part, right after that, the other arm put the other part.
4. Workspace similar to human-worker's = substitute for a worker.
 Neither specialized production line nor production system required for
introducing the robot.
 Able to maintain high productivity, without decreasing in concentration, even at
midnight.
 Cost reduction, comparing to labor costs in a long term.

 Dual-arm robot.
 Application example -1)
 Pharmaceutical industry:
 Medical product (immuno-chromatography: reagent for Influenza diagnosis).
Vacuum freeze-drying process (to prevent antibody devitalized).
 Image processing + Right arm (picking and aligning) + Left arm (dispensing
and coating/applying of reagent).
(Before)
• human worker did
inspection, aligning, and
dispensing.
(After)
• robot takes element out.
• after image inspection,
aligning to the tray.
• coating and dispensing
the reagent.

 Dual-arm robot.
 Cosmetics industry:
 Plastic packing of cosmetics of various kinds and small quantity.
 taking time and effort for robot teaching in every product replacement.
 Dual-arm robot + Supporting system.
 labor saving, reducing a mistake in the quantity.
(Before)
• three workers.
(After)
• product comes from
filling machine via
transfer conveyer.
• robot does packing.
• after packing, robot
does weighing and
verifying quantity.

 Dual-arm robot.
 Food industry：
 Dishing up foods into lunch container. Human-wave tactics, but labor shortage.
 3D image processing (ingredients recognition) + Dual arm (dishing up).
 labor saving (1310), decrease productivity due to recognition speed,
but increases workers' satisfaction.
(Before)
• dishing up manually.
(After)
• ingredients recognition by
3D image processing.
• grasping ingredients by
cooperative motions of two
arms.
• dishing up ingredients by
cooperative motion of two
arms.

Key-tech 2) Collaborative robot, Co-bot
 Collaborative robot, Co-bot.
 Working in the same space as human, together with human.
 Compared to conventional industrial robots, co-bots are:
1. Small-sized, lightweight, space-saving.
2. Without large-scaled safety system.
3. Powerless with small output power.
 Expansion of applications.
 Neither automotive nor electrical/electronics, but assembly, food,
medical, and cosmetic industries, and service industry.
 Developed and commercialized one after another.
KUKA, LBR
iiwa (2013)
Universal Robots,
UR3 (2015)
FANUC, CR-7iA
(2015?)
Rethink Robotics,
Sawyer (2015)
Yaskawa,
HC10DT (2018)

 Collaborative robot, Co-bot.
Car Workers and Robots Work
Hand-in-Hand [2016.07] (01:04)
Universal Robots' Five Unique
Selling Points - why cobots
[2016.01] (07:59)
Get More with FANUC
Collaborative Robots [2019.04]
(03:32)
Customer Success Story -
Steelcase, Inc. [2015.09] (02:11)
HC10 Collaborative Robot
[2018.09] (02:43)

 Reason of accelerated introduction:
1. Deregulation of smaller-than-80W actuator.
 Labor safety and health regulation, article 150 paragraph 4 prescribes that,
for industrial robots (using actuators of larger-than-80W of rated power output)
the fence or enclosure must be set to be secluded from human worker's
workspace when there is a risk of danger to contact with.
 The notification of Labor Standards Bureau in December 2013 says that the
situation evaluated as no-risk of danger for workers to contact with robot does
not apply to the case with a risk of danger.
2. Progress of safety technology.
 It was clearly stated that the measure, that the industrial robot manufactured
and settled according to the Safety Requirements ISO10218 (JIS B 8433) is
utilized based on these, is equivalent to setting the fence or enclosure.
 JIS B 8433-1:2015 (ISO 10218-1:2011) provides the guidelines for examination
to ensure the safety of robot itself in design and manufacturing.
 It describes the intrinsic danger source, the items to consider to remove and
reduce the risk, and so on.
 JIS B 8433-2:2015 (ISO 10218-2:2011) provides the guidelines for the safety
protection of robotic system integration, installation, functional test,
programming, operation, maintenance, and inspection.
 It also defines safety requirements of cooperative robots for system integrators.

ISO 10218-1:2011
Robots and robotic devices -- Safety requirements for industrial robots --
Part 1: Robots.
1. Scope.
2. Normative references.
3. Terms and definitions.
4. Hazard identification and risk assessment.
5. Design requirements and protective measures.
5.1. General. 5.2. General requirements. 5.3. Actuating controls. 5.4. Safety-related control system performance
(hardware/software). 5.5. Robot stopping functions. 5.6. Speed control. 5.7. Operational modes. 5.8.
Pendant controls. 5.9. Control of simultaneous motion. 5.10. Collaborative operation requirements. 5.11.
Singularity protection. 5.12. Axis limiting. 5.13. Movement without drive power. 5.14. Provisions for lifting.
5.15. Electrical connectors.
6. Verification and validation of safety requirements and protective measures.
6.1. General. 6.2. Verification and validation methods. 6.3. Required verification and validation.
7. Information for use.
7.1. General. 7.2. Instruction handbook. 7.3. Marking.
Annex A (informative) List of significant hazards.
Annex B (informative) Stopping time and distant metric.
Annex C (informative) Functional characteristics of three-position enabling device.
Annex D (informative) Optional features.
Annex E (informative) Labelling.
Annex F (informative) Means of verification of the safety requirements and measures.
Bibliography.

ISO 10218-2:2011
Robots and robotic devices -- Safety requirements for industrial robots --
Part 2: Robot systems and integration.
1. Scope.
2. Normative references.
3. Terms and definitions.
4. Hazard identification and risk assessment.
4.1. General. 4.2. Layout design. 4.3. Risk assessment. 4.4. Hazard identification. 4.5. Hazard elimination
and risk reduction.
5. Safety requirements and protective measures.
5.1. General. 5.2. Safety-related control system performance (hardware/software). 5.3. Design and installation.
5.4. Limiting robot motion. 5.5. Layout. 5.6. Robot system operational mode application. 5.7. Pendants. 5.8.
Maintenance and repair. 5.9. Integrated manufacturing system (IMS) interface. 5.10. Safeguarding. 5.11.
Collaborative robot operation. 5.12. Commissioning of robot systems.
6. Verification and validation of safety requirements and protective measures.
6.1. General. 6.2. Verification and validation methods. 6.3. Required verification and validation. 6.4. Verification
and validation of protective equipment.
7. Information for use.
7.1. General. 7.2. Instruction handbook. 7.3. Marking.
Annex A (informative) List of significant hazards.
Annex B (informative) Relationship of standards related to protective devices.
Annex C (informative) Safeguarding material entry and exit points.
Annex D (informative) Operation of more than one enabling device.
Annex E (informative) Conceptual applications of collaborative robots.
Annex F (informative) Process observation.
Annex G (informative) Means of verification of the safety requirements and measures.
Bibliography.

Research project
 Integration of cooperative robot.
aiming at human-robot symbiotic manufacturing.
 Purpose)
 Considering a cooperation form of human and robot working on
the same object to achieve some task in industrial field.
 Subject)
1. Process planning of cooperative work.
2. Motion teaching for cooperative work.
3. Mutual communication between human and robot.
4. Others.
 Conventional usage of co-bot.
 Replacement of human worker.
 Worker and robot work side-by-side in an assembling line,
but doing individual/separate task.
 Giving the most importance is on unnecessary safety fence even when
overlapping their working range and active area.
 Human worker will be replaced by robot one-by-one.

Human-robot relationship at work
1. Sharing [分担].
 A series of work is divided into multiple work elements.
Every work elements are assigned as a role to each worker.
 Ex.) Toyota Motor Corporation.
 Machines and robots.
 dirty work, physically-hard work, repetitive work exactly in the decided procedure in
a set period of time.
 Human-worker.
 works necessary to judge like assembly and inspection, works only learned through
actual experience.
 Working processes by human and robot can be separated
and independent.

2. Coordination [協調].
 Take on some work together, like coordinated transport.
 Space).
1. Present type.
 sharing a workspace and working closely.
2. Remote type.
 working in a place difficult or dangerous for human-worker to approach.
 Time).
1. Synchronous type.
 exchanging power and information in real-time.
2. Asynchronous type.
 human command and robot execution are not necessarily at the same time.
 Initiative).
1. Parallel type.
 stand side-by-side in equal.
2. Integrated type.
 like powered exoskeleton to become unified, human wears a robotic mechanism.
 Through the same object, maintaining mutual interaction
both physically and informationally.

3. Coaction / Collaboration / Cooperation
[共同 / 協同 / 協働].
 Work together to achieve a common goal.
1. Coaction [共同].
 Under the same condition and having the same qualification.
2. Collaboration [協同].
 Cooperate with each other, putting mind and power together.
 emphasizing on mental aspect.
3. Cooperation [協働].
 Sharing a sense of purpose, toward a common objective, taking advantage of
each characteristics, making one's best.
 keeping independence and autonomy of each subject.
 seeking a synergistic effect, supplementing individual ability and resource.
 taking appropriate responsibility for their own achievements and results.
 Cooperative work [協働作業].

Examples of Cooperative work
 Ex-1) Japanese rice cake [mochi] pounding.
 Steamed rice is mashed and pounded into paste
in traditional stone/wooden mortar [usu]
by wooden mallets [kine].
1. One pounding.
 drops down naturally by the self-weight of a lifted mallet.
2. The other turning and wetting.
 turn it over, and centralize it like folding.
 Keeping a steady rhythm to prevent accident.
FAST POUNDING MOCHI Rice
Cake Japanese Street Food
Nishiki Market Kyoto Japan
[2019.01] (05:04)

 Ex-2) String figures / Cat's cradle.
 Played with string looped over the figures to involve creating
various string figures, either individually or by passing a
loop of string back and forth between two or more players.
1. begins with one player making the eponymous figure "Cat's Cradle".
2. next player manipulates that figure and removes the string figure
from the hands of previous player to create another figure.
3. ends when a player makes a mistake or creates a dead-end figure,
which cannot be turned into anything else.
How to do Cat's Cradle EASY!
Step by step, with string [2013.08]
(04:35)

 Ex-3) Mountain demolishing game.
 Sand hill scraped as a outdoor playing for children.
1. at the top of sand hill, let a stick stand by sticking it.
2. sand hill surrounded by both hands, and scrape sand from both
sides of sand hill, while prevent falling a stick down.
3. in one's turn, one who falls a stick down loses the game.
 determining is the essential how much sand can be scraped.
【2003年の】砂山崩し【FLASH
ゲーム】 [2019.07] (06:15)

 Ex-4) Balancing game.
 Jenga --- pulling out and stacking up type.
1. Tower staking 54 rectangular blocks in 18 layered.
2. A player pull out one block and put it on the top.
3. A player who destroy the tower loses.
 Kawada balance tower --- putting up type.
1. Roll the die and put the doll in the appeared color.
2. Doll felt from the tower must be collected by the previous player.
3. Doll is no longer the first person wins.
元祖ぐらぐらゲームで遊んで
みた！ [2018.03] (03:23)

Research subjects -1
1. Process planning of cooperative work.
 Role and positioning of human and robot.
 Which stance to adopt ?
 Human --- parts in need for craftsmanship.
Robot --- simple and easy parts, like preliminary arrangements.
 Ex.) robot (pre-assembly) and human (main-assembly).
 Ex.) robot (printing, labeling) and human (visual examination with one’s sensitivity).
 Human --- setup for robot.
Robot --- complex and difficult parts, parts in need for speed and precision.
 In the near future, due to no longer experienced/skilled worker, craftsman/artisan.
 Even non-permanent worker or temporary worker can do.
 Process visualization and role assignment.
 Understanding of work contents and work procedures.
 Planning method of machining and assembling processes from drawing.
 Teaching-less and intelligent teaching.
 Skill (content, level) quantification method both of human and robot in charge.
 Labor allocation technique to maximize individual abilities.

2. Motion teaching for cooperative work.
 Simplification of programming and teaching.
 Heavy workload of frequent teaching after usual "improvement
activity“ and/or change-over in manufacturing line.
 Easy teaching:
 Direct teaching (waypoint, trajectory) --- safety.
 Offline teaching --- user interface, virtual environment (physical model), etc.
 Intelligent teaching and teaching-less.
 Motion library.
 Robot motion planning library --- parameters setting, adjustment of transitions.
 Automatic motion generation.
 Machine learning (deep reinforcement learning) --- by designing policy, reward,
and action to generate proper operations even from abstract requirements.
 Object recognition – robot motion.
 Machin vision (ex. shape pattern recognition) and automatic generation of
motion to manipulate it.

3. Mutual communication between human and robot.
 Estimating behavior and understanding intention of
human.
 From external appearance without wearing any sensor device.
 image from a 3D (RGB-D) camera, data from a motion capture system, etc.
 Method (estimation, prediction, identification, classification).
 to extract useful information.
 Transmission between human and robot.
 Conventional --- slinging work (goods transfer).
 cues by arm, flag, (and whistling) to instruct the place to transfer the goods.
 limited vocabulary of gestures, not easy to communicate even among human.
 Conventional --- co-acting (worker and robot).
 worker --- press a switch after finishing assigned task.
 robot --- turn on a signal after finishing assigned task.
 Multi-modal communication methodology.
 a set of communication with variety of expression.
 gesture classification, face recognition, gaze detection, speech recognition, etc.

Development of Production System and Robotic Manufacturing.

Recommended

Recommended

More Related Content

Similar to Development of Production System and Robotic Manufacturing.

Similar to Development of Production System and Robotic Manufacturing. (20)

Recently uploaded

Recently uploaded (20)

Development of Production System and Robotic Manufacturing.