Robotic systems are designed to perform unsafe, dangerous, and repetitive tasks that require movement of material, parts, tools, or other devices through set motions. With so many applicable functions, it’s clear why standard robotics have been a part of the industrial process for decades and will continue to be utilized in the future. More additions bring more success stories, updated standards, and a basic roadmap for robotic implementation in your facility.
Whether you have already identified pain points that could be solved with the introduction of industrial robots or your staff is simply excited by the idea of adding standard robotics to daily operations, you likely have questions when it comes to next steps. The most successful deployments follow a repeatable process of research, preparation, implementation, training, and documentation.
Examine Opportunities
Start by identifying processes where robotic systems can remove repetitive strain, reduce exposure to potential hazards, or stabilize quality. Good early candidates are predictable tasks with high volume and variation, such as palletizing, welding, dispensing, packaging, machine tending, and more.
Industrial robots come in various shapes, sizes, and structures for various uses. They are classified based on human interface, ranging from collaborative to non-collaborative. Classifications split robots into four typical structures:
- Articulating robots that possess at least three rotary joints. These are often used to replicate the motion of a human arm and can handle light to heavy loads.
- Selective Compliance Assembly, or Articulated, Robot Arm (SCARA) robots use two parallel rotary joints and assist with assembly operations.
- Cartesian robots are also known as linear robots, XYZ robots, or gantry-style robots. They can carry heavy loads and often assist with loading and unloading, plotting, 3D printing, tool calibration, and more.
- Parallel robots utilize cables, rods, or chains that are controlled separately, and they perform high-speed operations, assembly, platform movements, and are commonly used for pick-and-place operations.
Strategically selecting tasks that are well-suited for robotic intervention allows you to write out a list of requirements and compare options to meet your facility’s needs.
Vendor Communication and Cell Considerations
Once the robot type and application or tasks to be performed are determined, the next steps include communication with vendors to determine what actual technologies will be implemented and if any adjustments to the facility need to be considered. This includes designing the cell layout and operations of the robot, system, and ancillary equipment (e.g. conveyors, palletizers, etc.).
Part of the communication with vendors includes interaction with the integrator, who will be responsible for the design, building, and installation of the system and its components. Per ANSI/A3 R15.06 Part 3 – User Requirements, the statement of work (SOW) outlines the integrator’s obligations set forth by the user and can be a reference document in the contract between the user and the integrator. If an SOW is developed, it shall include the technical content of the specification for the robot system as well as the responsibilities of all the parties involved. The SOW should require that the information for use from the integrator includes a statement of the residual risk in accordance with ANSI/A3 R15.06-2025 Part 2, Clause 7.1. The SOW shall clearly specify the safety system requirements when interaction or integration with adjacent and/or ancillary equipment (e.g., SRP/CS handshaking) is required.
As mentioned, being involved in the risk assessment, or having a discussion of residual risk within the system is vital. You as the “user” should be involved in this process throughout the process, including either participating in the integrator’s risk assessment or discussing any residual risk within the system with them. The user’s involvement in the risk assessment process enables the identification of effective risk reduction measures and establishing an overall safety strategy.
In accordance with ANSI/A3 R15.06-2025 Part 3, Clause 6, the User of the system shall conduct a risk assessment of the system as it is built and utilized by facility operations.
Perform a Risk Assessment
Next, identify potential hazards and limits for the intended robot application and its lifecycle, which includes installation, setup, operation, troubleshooting and maintenance, and decommissioning. This process must be completed for each device you consider, as no two systems are exactly alike. Include those who understand both the process and the robotics: operators, maintenance personnel, engineers, system integrators, and original equipment manufacturers (OEMs) as you gather data in this step.
Consider which regulations and standards will apply to your facility and robotic implementations. The Occupational Safety and Health Administration (OSHA) Technical Manual (OTM) Section IV: Chapter 4 provides guidance for robotics. OSHA also enforces robot safety through applicable standards, specifically subparts of 29 CFR 1910, including machine guarding (subpart O), lockout/tagout (subpart J), and electrical safety (subpart S). Voluntary consensus standards from the American National Standards Institute (ANSI), Association for Advancing Automation (A3), International Organization for Standardization (ISO), and other organizations should also be complied with.
Specific standards, such as ANSI/A3 R15.06, ANSI B11.0, and ISO 12100 provide detailed guidance on conducting risk assessments for robot systems. ANSI/A3 R15.06 Part 3 states the user requirements to which OSHA has been trained, and provided with field guides covering this, and will be using when working with facilities.
Conversion Technology, Inc. (CTI) uses a Risk Assessment Methodology that assigns numeric values to risks and hazards based on likelihood and frequency of occurrence. This allows for an objective appraisal of the associated risks of implementing a new piece of machinery. CTI can provide a detailed report identifying safety deficiencies and specific recommendations for your facility to comply with all applicable standards.
Prepare for Implementation
Industrial robotics are successfully implemented when the facility is ready for the robot, not when the robot is ready for the facility. Clear, consistent communication both within the company and externally ensures that everyone is on the same page when it comes to expectations, roles, and objectives. Address staff concerns that may arise, highlighting how robots typically handle dangerous and monotonous tasks.
Confirm any necessary utility upgrades and modernization efforts are completed on time. Power, compressed air, water, and other utility services may need to be rerouted or added. Lighting, temperature, and humidity might require adjustments for proper operation. And before finally bringing the robotic system into your facility, ensure the area is clear, free of dust, and properly marked off. Additionally, it is important to ensure all parties involved are following a specified acceptance protocol for the system, as well as any residual risk is communicated and mitigated, as applicable.
Implement Safeguarding and Safety Procedures
Use data from risk assessments completed during each stage to select safeguarding methods that match the real hazards and scope of operation. Consider safety protocols not only for workers who operate the robot daily, but also those who program, maintain, repair, and troubleshoot the system.
Common robot safety devices and practices include:
- Fixed barrier and perimeter guards
- Presence-sensing devices, including safety light curtains, scanners, or safety mats
- Interlocked gates
Safeguarding is only part of establishing a safe work environment with robotics. Establish procedures for lockout/tagout (LOTO), implement standard operating procedures (SOPs), define who can enter restricted areas and under what conditions, clearly define restricted spaces using barriers and signs, and ensure a clear method for mode selection that includes appropriate access levels. Ensure all facility personnel are properly trained per their role. Provide appropriate Personal Protective Equipment (PPE) that meets OSHA’s PPE standards, and instruct workers on how to properly wear, maintain, and dispose of their equipment.
Train and Document
Build a role-based training program that allows operators, engineers, and supervisors to understand what normal operation looks like and what to do when something deviates. Training should include hands-on walkthroughs and refresher training after significant process changes or incidents.
Maintain up-to-date documentation that includes all risk assessments and risk reduction decisions, schematics, test results, operation, and maintenance instructions, LOTO procedures, documentation from the Integrators, cell acceptance protocols, and more. Keep detailed logs for safety inspections, repairs, and program changes, and schedule routine inspections and functional checks of safety devices in advance. Well-kept documents can reduce downtime, protect employees, speed up troubleshooting, and ensure compliance with appropriate standards.
Robotics can give your facility a competitive advantage, but implementing the technology is only one part of the transformation. In-depth research and development from start to finish allows your facility to reduce surprises and enjoy the benefits of industrial robots quickly, safely, and efficiently.
CTI is an Associate Member of the ANSI/A3 R15.06 and R15.08 Rulemaking Committees and part of the OSHA-A3-NIOSH Alliance Committee, with direct contributions to the Robot Safety sections in OSHA’s Technical Manual, OSHA’s Field Guide for OSHA’s safety officers, and providing the training to OSHA on the subject of robots and robot systems. Contact CTI today to learn how our industry-leading experience allows us to assist your facility in improving safety procedures and complying with all standards and regulations.