APRIL Launch Event - Kuka - Intersector Knowledge Transfer Opportunities

Inter-Sector
Knowledge
Transfer
Opportunities
Jeff Nowill; CEO, KUKA Robotics
National Centre for Food Manufacturing, 28/04/16

APRIL Launch - Intersect
Jeff Nowill; CEO, KUKA Robotics – 28th April, 2016

UOL, OAL APRIL Launch Event
Precis: Worldwide shipments of multipurpose industrial robots are forecast to exceed 207,000 units in
2015, up from around 159,000 in 2012.
This tremendous growth is largely driven by the automotive sector which accounted for almost 60 percent
of new industrial robot installations by 2011. Consequently, the robot density is particularly high in
countries with a strong automotive industry….
In Japan, there are 1,562 industrial robots installed per 10,000 automotive employees…..
Demand for robots in China reached 45,000 units in 2014 and is projected to exceed 100,000 units by
2017, or 40% of the global market.
The current market for robots in the UK is closer to 1,500 robots per annum, or 3% of the current Chinese
demand. Luckily, China isn’t a significant exporter of foods…..

www.kuka-robotics.com
15-year analysis of the UK Industrial Robot market
General Industry Tier One Auto Total
1 1999 255 225 390 870
2 2000 346 261 606 1213
3 2001 322 274 232 828
4 2002 303 293 121 717
5 2003 254 175 383 812
6 2004 330 212 498 1040
7 2005 393 225 439 1057
8 2006 353 194 127 674
9 2007 364 150 116 629
10 2008 374 106 104 584
11 2009 429 67 52 548
12 2010 521 140 135 796
13 2011 497 387 452 1336
14 2012 459 394 1574 2427
15 2013 575 624 1106 2305
16 2014 662 323 808 1793
17 2015 0
15 year average 385 248 422 1056
The bold font in 2012 and 2013 correspond to JLR’s investment in new robotics and automation

Example of investment in robotiocs increasing revenues - JLR
Key JLR numbers, post-investment in new automation:
Year ending March 2012: Turnover £13,512m; EBITDA £2,027m, Net income £1,507m
Turnover increase: +62% in 4 years

Example of investment in robotiocs increasing output - ARLA
Background: Arla Foods AB planned to introduce a new product to its range.
In order to cope with the increased product volumes this would entail, a high-performance system was needed which would also
be able to handle two types of carton, 2-litre and 1 litre Tetra Paks. Previously, the cartons were palletized manually.
Now, 600 to 700 pallets can be processed every week. That is equivalent to 5,000 juice cartons per hour which are palletized by
the KUKA robot.
Previously, only 50 to 100 pallets a week could be managed. The system runs 24 hours a day, 6 days a week.
From a palletising perspective; practically all labour was saved, and a 700% increase in output achieved

Internationally acknowledged comparison of installed robots per 10,000 workers
# Country 2005 2006 2007 2008 2009 2010 2011 2012 2013
12/13
change
1 Germany 216 228 234 244 255 263 270 273 282 3.3%
2 Sweden 119 124 130 138 153 154 158 164 174 6.1%
3 Belgium 107 112 112 111 120 121 121 144 169 17.4%
4 Denmark 75 85 97 105 123 139 146 156 166 6.4%
5 Italy 137 142 147 151 156 163 161 160 153 -4.4%
6 Spain 83 90 96 101 119 127 135 138 141 2.2%
7 France 94 102 108 112 117 123 124 124 125 0.8%
8 Finland 105 109 112 114 125 127 125 121 122 0.8%
9 Austria 70 73 78 83 91 98 102 110 118 7.3%
10 Netherlands 39 45 52 57 64 68 77 84 93 10.7%
11 Slovenia 21 26 32 39 46 56 64 81 90 11.1%
12 Slovakia 12 12 14 17 24 45 49 50 83 66.0%
13 Switzerland 56 57 60 62 63 63 67 75 79 5.3%
14 Czech Rep 17 11 26 32 37 40 52 60 72 20.0%
15 United Kingdom 53 56 58 59 60 59 60 64 66 3.1%
16 Hungary 5 7 9 12 15 18 30 42 47 11.9%
17 Norway 34 38 39 39 41 42 43 42 44 4.8%
18 Portugal 18 20 22 25 28 31 32 37 41 10.8%
19 Israel 6 8 11 13 16 18 20 22 23 4.5%
20 Poland 3 4 6 8 10 12 14 17 19 11.8%
21 Greece 2 2 3 5 6 8 9 11 13 18.2%
22 Turkey 1 2 3 4 5 6 8 10 13 30.0%
23 Romania 0 0 1 1 1 2 5 6 7 16.7%
24 Estonia 0 0 0 1 3 3 4 5 6 20.0%
But the UK still lags way behind....

Focus on the Food and Drink sector
Industry Sector
Automotive 151 519 8 130 808 182 76 22 44 324
Auto components 110 82 79 52 323 92 45 71 58 266
Metal manufacturing 36 29 15 52 132 9 28 20 31 88
Plastics 26 34 46 39 145 41 14 37 48 140
Electrical/Electronic 5 10 14 16 45 4 4 7 10 25
Aerospace 4 12 4 4 24 0 1 1 1 3
Pharma, healthcare, medical 21 23 19 22 85 17 18 25 23 83
Education/R & D 22 9 14 14 59 16 10 17 15 58
Food and drink 36 7 20 19 82 12 37 16 29 94
Other 20 27 24 19 90 24 19 21 22 86
Total 431 752 243 367 1793 397 252 237 281 1167
What robots UK manufacturer do buy are heavily weighted towards the automotive sector:
- Automotive and T1 sectors traditionally count for 50 – 65% of all robots bought
- Food and drink sectors only account for 4 to 8% of current purchasing (constant 10-year
average, 63 of 1,212 in 2000, so 5.2%)
(to include 4, 5 and 6-axis robots, SCARA and delta-style devices)

Food and Drink: an ideal market for further robotic uptake
Despite less then 10% of the UK’s robot stock being destined for the Food and Drink
sector; the arguments in favour of the use of robots in the market are overwhelming:
- Availability in excess of 99.99%
- Operator safety
- Service life circa. 10 years+
- Reduce wastage and increased quality, as a robot is positionally repeatable to +/-
0.05mm
- Small robots start at 50% of UK average wage
- Reduced worker movement to and from production areas
- Flexible manufacturing (Industry 4.0)
- Absolute product traceability
- Difficulty with manual-labour negated: potential for injury, repetitive tasks, and the
high speed of the lines

Application areas – still simple & primarily downstream
PRIMARY/Upstream SECONDARY/Downstream
Process Packaging
Loading/Unloading of
 Thermoformers
 Flowwrappers
 Traysealers
 Cartons
 …
Case Packing
Picking
Packing
Destacking
 Grouping
 Stapling

Solutions for end-of-line palletising: long-standing

Moving robot use closer to process, and the future....
Water-proof robots:
- Clean-down in
abattoir situations
- Hydrogen peroxide
resistant machines
for mitigation of
contamination
Known process competences:
- Handling
- Packing
- Scoring
- Cutting / butchery
Developing competences:
- 3-D bin picking of organic
products
- Automated vision
inspection / checking of
organic products

Mobile robotics
The potential use of mobile robotics in the Food
and Drink sector is immense. The use of the
OmniMove product in the aerospace sector has cut
handling time in excess of 500%; and station-to-
station times almost 4-fold

Industry 4.0, and the Food and Drink market
Few industries are as appropriate to an Industry 4.0 / Smart Factory solution as the Food and
Drink supply chain
The ‘bridge’ between consumer, supplier and producer can be as short and efficient as
possible
Fully-flexible manufacturing, with an automated solution, can bring an unrivalled ‘integrated
solution’

Collaborative Robots (CoBots): The Future……
Industrial robots are caged to keep humans safe and out of harm’s way
Service robots are meant to safely leave the cage while doing tasks for humans
Collaborative robots come in all sizes and shapes and have integrated sensors and soft and
rounded surfaces for safety purposes and to reduce the risk of impact, pinching and crushing.
The biggest safety feature of collaborative robots is their force-limited joints, which are
designed to sense forces due to impact and quickly react; and CoBots are designed to work
alongside workers

Collaborative Robots (CoBots)
In a human-machine study conducted by MIT researchers at a BMW
factory, it was shown that teams made of humans and robots
collaborating efficiently can be more productive than teams made of
either humans or robots alone. Also, the cooperative process
reduced human idle time by 85 percent.
The collaborative robotics sector is expected to increase roughly tenfold between 2015
and 2020, reaching over US $1 billion from approximately $95 million in 2014
There are many reasons for the emergence of collaborative robots: companies are using
them because they can be placed alongside humans and they are affordable and easily
trainable; and because they are flexible to handle short runs, repetitive and boring jobs,
and ergonomically challenging tasks.
Market appropriate thought: The increased sensitivity could make the product ideal for
ingredient mixing?!?

Many thanks for listening......
Any questions?

APRIL Launch Event - Kuka - Intersector Knowledge Transfer Opportunities

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