Automation without barriers

RECENT RESEARCH from Make UK found that approximately 36 %of manufacturing vacancies are difficult to fill due to candidates lacking the necessary skills, qualifications or experience. Collaborative robots are becoming an increasingly important tool for manufacturers in addressing this gap. By taking on repetitive, physically intensive and potentially hazardous tasks, cobots enable businesses to sustain production levels despite ongoing workforce challenges.

In addition to helping bridge labour gaps, cobots deliver consistent performance that supports improved productivity and product quality. What’s more, they allow human employees to concentrate on more complex value-adding activities that require problem-solving, judgement and expertise. Reduced physical strain can also contribute to improved workplace wellbeing, while intuitive programming lowers barriers to adoption by reducing training requirements and implementation times. For many manufacturers, these advantages help accelerate return on investment.

Navigating new regulations

Across manufacturing operations, cobots are increasingly utilised to streamline assembly processes and improve operational workflows. A 2024 study published in Frontiers in Robotics & AI showed that collaborative robots can boost productivity by automating repetitive activities while leaving more complex, cognitively demanding work to human operators. 

Adoption continues to grow, with the International Federation of Robotics estimating that 10.5% of all industrial robots installed in 2023 were cobots. Regulatory requirements are now evolving in parallel with technological progress. The EU Machinery Regulation 2023/1230, adopted in 2023 and scheduled to apply fully from January 2027, replaces the previous Machinery Directive. It introduces more robust expectations around safety, responsibility and cybersecurity for advanced machinery and collaborative systems. These changes encourage greater transparency and more rigorous conformity procedures, signalling that compliance and safe integration will become increasingly important considerations for automation projects.

For engineers, the implications extend directly to how collaborative robotic systems are designed, deployed and validated. Within logistics environments, cobots are increasingly used for palletising, order picking and intralogistics material handling. Technologies such as machine vision, force sensing and safety-rated scanners allow close human–robot interaction without the need for conventional safety cages. 

In automotive production, collaborative robots support tasks including precision assembly, screwdriving, machine tending and quality inspection, helping improve cycle-time consistency while reducing operator fatigue and ergonomic strain.

Successful integration depends on following established best practices. This includes carrying out task-specific risk assessments in accordance with ISO 12100 and ISO/TS 15066, implementing safety-rated monitored stop functions and speed-and-separation monitoring, and maintaining strong cybersecurity controls for connected robotic systems. Engineers should also consider modular architectures, standardised industrial communication protocols such as PROFINET and EtherCAT, and digital simulation platforms that enable layouts and workflows to be validated before installation.

Challenges in legacy manufacturing environments

Many manufacturing facilities continue to rely on ageing infrastructure and legacy equipment that was never designed with robotics in mind. Restricted floor plans, outdated systems and inconsistent connectivity can complicate introducing automation. If new technologies are not compatible with older assets, implementation can quickly become complex, time-consuming and expensive.

The success of collaborative automation depends on more than the robot itself. Programming, setup and configuration, software integration and ongoing maintenance may exceed the expertise of a team. Initial investment costs, from the initial equipment itself to any necessary facility upgrades and workforce training can also appear significant, particularly in today’s often turbulent economic landscape.

Traditional industrial robots, typically engineered for fixed and repetitive applications, often require extensive reprogramming in response to any changes in production requirements. The resulting downtime can rapidly undermine their benefit and limit long-term value. To overcome these limitations, manufacturers are increasingly turning to flexible automation strategies that emphasise rapid deployment, simple reconfigurability and scalable investment models, particularly within small and medium-sized operations.

For example, CubeBOX EcoLEAN-V1 and V2 are designed to be repositioned and reconfigured as production needs evolve. This adaptability enables manufacturers to expand automation gradually across their operation without committing to fixed production layouts. The approach reflects a wider industry move towards agile automation — solutions capable of evolving alongside changing operational demands. EcoLEAN is available in a range of configurations to accommodate different payloads, component sizes and space limitations, making it suitable for a variety of manufacturing settings.

The right investment

According to a 2025 Deloitte survey of 600 manufacturing executives, 80 per cent expect to allocate at least 20 per cent of their improvement budgets to smart manufacturing initiatives this year, with investment focused on foundational technologies and digital capabilities.

This level of commitment signals a clear industry shift: manufacturers are no longer viewing digitalisation and automation as optional upgrades, but as essential capabilities that will define competitiveness in the years ahead. This level of commitment is indicative of a broader shift in thinking across the sector. Manufacturers increasingly regard automation and digital transformation not as optional enhancements, but as critical capabilities that will shape competitiveness in years to come.

While collaborative technologies remain a major driver of this transition, factors such as flexibility, mobility and affordability will ultimately determine how manufacturing operates, how widely automation is adopted and who can benefit from its advantages.

Hakan Aydoğdu is CEO of Tezmaksan Robot Technologies

tezmaksanrobotics.com