Manufacturing companies have been automating processes and utilising robotics for decades. But when it comes to the use of robots, in Ireland at least it looks like someone has pulled the plug.
A 2023 report found the Republic had just 54 industrial robots per 10,000 employees in manufacturing, significantly lower than other advanced economies.
Germany had 397, for example. Even the UK, seen as a laggard in robotics and automation uptake, had 111 – more than twice the robot density of the Republic.
Little wonder the topic featured in Engineering Industries Ireland’s pre-budget submission last year. The organisation, which was set up in 2021, is the Ibec sector representing the engineering manufacturing and engineering services companies in the State.
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It includes more than 150 member companies spanning industrial automation, precision engineering, agriculture machinery, materials handling, energy and environment, automotive, metal fabrication, and printing.
As such, it has a vested interest in ensuring the Republic keeps pace with international developments in manufacturing.
It has called for an accelerated capital allowances scheme for advanced manufacturing, similar to the UK, and for investments in connected machines, advanced automation, robotics and digital technologies in manufacturing to drive digitalisation.
Already talk has moved on from industry 4.0, the term used to describe the trend of increased automation and data exchange, to industry 5.0, which includes the rise of robots, particularly collaborative robots, or cobots.
More than simply automated, connected machines, cobots are designed to work alongside humans, with sensors and safety features to keep everyone safe, and with no concerns about Safepass training or back strain.
According to figures published by the International Federation of Robotics, robot adoption in factories elsewhere is continuing at speed. Average robot density globally reached 162 units per 10,000 employees in 2023 – more than double the number just seven years previously.
Given that robot density is a barometer for the degree of automation adoption in the manufacturing industry around the world, the lag here is a concern for Ireland Inc.
Indeed, we clearly have a way to go, and not just in relation to robots but even in terms of simple automation, says Pat Phibbs, managing director of ALS Identify, a specialist in the design and build of custom labelling and identification systems.
“While automation has been a part of the manufacturing vernacular for decades, you’d still be surprised by what is still being done either manually or without fully embracing the benefits of digitalisation. But with the need to produce more at lower cost and without increasing production space, manufacturers are looking for ways to optimise their workforce and workspace, and automation is where they can have the biggest impact,” says Phibbs.
“Our customers are now looking at how to introduce AI and machine learning into their automation processes to enhance precision, increase efficiency, embrace customisation and comply with rigorous standards, particularly in the food and life sciences sectors.”
The latest advancements in automation and robotics will help manufacturers to free up one of their most valuable resources, Phibbs points out: employee time.
“Automation allows employees the time to upskill and grow with the company to fill new roles within the business that require human intervention and intelligence instead of repetitive tasks that a robot can do,” he explains.
The solutions it builds for customers are typically a combination of conveyors, labelling and vision systems that are automated and enhanced with AI.
“Repetitive tasks such as applying labels, closing lids, turning product on a conveyor are automated, saving hundreds of labour hours a week. AI is deployed to end-of-line processes to perform tasks such as defect and error detection by recognising when a label is applied incorrectly or applied to the wrong product,” says Phibbs.
“It runs a number of imaging checks and makes the decision to stop the production line or to divert the defective product off the line for further inspection. This is crucial for the life sciences section, where traceability and accuracy are paramount to ensure product safety, regulatory compliance and patient trust.”
With geopolitics now feeding into Irish insecurities around the big multinationals based in the State, particularly US foreign direct investment, any move by Government to help the indigenous manufacturing sector will be very welcome indeed.
