Automation and robotics are important parts of industrial change, including electronics manufacturing. Although the terms are often used interchangeably, they describe different approaches. Together, they can improve efficiency, precision and production costs. What does this mean for electronics manufacturers?
Automation and robotics: basic definitions
Automation replaces selected manual activities with machines or digital systems that follow programmed instructions. Examples in electronics manufacturing include soldering surface-mount devices (SMDs) and programming microcontrollers.
Robotics is the use of robots to perform tasks. Depending on their design, robots may use sensors or AI to respond to changing conditions; this is not a requirement for every robotic system. In electronics manufacturing, applications include PCB handling by collaborative robots, known as cobots, and automated device testing.
Why automation and robotics matter to electronics manufacturing
Automating suitable production tasks can help electronics manufacturers remain competitive. Potential benefits include:
- Greater precision and repeatability: robots can perform repetitive operations consistently, including handling and processing small components on PCBs.
- Production-cost optimisation: the initial investment can be substantial, but higher throughput and fewer process errors may reduce long-term costs. The business case depends on utilisation and the application.
- Faster production: automated lines can increase throughput and help fulfil larger orders within an agreed schedule.
- More flexible processes: programmable robotic systems can be adapted to different production requirements, subject to tooling, programming and validation.
- Better working conditions: reducing repetitive or physically demanding tasks allows people to focus on supervision, engineering and process improvement.
Benefits for manufacturing businesses
Shorter production cycles and cost optimisation
Robots can shorten repetitive operations and help maintain consistent throughput. Automated soldering, for example, can be faster than manual methods for suitable production volumes. Equipment still requires maintenance, setup and monitoring; automation does not eliminate every source of downtime.
Cost optimisation can also come from reduced material waste and fewer assembly errors. A controlled, repeatable process can reduce the need for rework.
Improving product quality through repeatability
Robotic equipment can support consistent quality by repeating operations within defined process parameters. This matters in electronics, where small assembly defects may affect the operation of an entire device. The result depends on process development and validation rather than the presence of a robot alone.
For example, an automated functional-test station can check a device against an agreed sequence before shipment. At Techbit, functional testing is defined for the project, with the customer providing the tester and instructions where applicable.
How is robotics introduced into production?
Implementation starts with an analysis of the company's requirements and an investment plan. The main stages are:
Needs analysis and system design: identify processes suitable for automation and prepare a technical design reflecting their requirements.
- Technology and equipment selection: choose industrial robots, cobots or assembly systems suited to the intended production.
- Installation and integration: install the equipment within the production environment and integrate the control software.
- Testing and optimisation: validate the system before release, address problems and adjust the process for reliable performance.
- Employee training: teach the team how to operate, supervise and maintain the technology in daily work.
Examples of processes that can be automated
- Automated SMT and through-hole assembly: suitable machines position components on PCBs with repeatable accuracy.
- Microcontroller programming: automated stations can program integrated circuits at production scale.
- Functional testing: automated equipment can check specified device functions and identify failures.
- Conformal coating and PCBA cleaning: automated processes can help apply repeatable cleaning and protective treatments.
Automation of these operations can improve efficiency and consistency while helping manufacturers respond to changing market requirements.
The future of automation and robotics in electronics
AI and the Internet of Things (IoT) can support more detailed data analysis and help identify potential problems in production.
Collaborative robots can also support tasks in shared workspaces, opening possibilities for smaller production facilities. Each application still requires appropriate safety assessment and system integration.
More flexible automation may make smaller, customised batches easier to produce. Reducing manual operations does not remove the need for people: engineering, supervision, maintenance and decision-making remain essential.
Why consider investing in robotics?
Robotics and automation can help manufacturers improve costs, throughput and quality. The strongest investments address a specific production problem and have a clear business case. An appropriate system can also give the company more flexibility as customer and market requirements change.