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Senior Capstone: Utilizing Cobots in Pharmaceutical Packing

Team 8: Cobots

Fritz, Austin; Hock Othul; Johnstone, Abigail;

Munoz, Jasmyn; Nacht, Benjamin

Project Advisor: Dr. Christopher Greene

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Agenda

Problem Statement & Objective
Research

iA Pharmaceuticals
Cobotics
Simulation

Milestones
Simulation Models

RoboDK
Visual Components
Real Life UR5

Data and Financial Analysis
Conclusion

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Problem Statement

Pillars of Industry 4.0 are providing a paradigm shift in the methodology engineers are utilizing to develop processes and services. Research is needed to effectively develop the application of these pillars. This research examines autonomous robotics, namely cobots, and possible utilization through the use of real-world programming and simulation.

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Project Objective

Develop a cobotics-based system for picking and packing in a manufacturing or service environment, for example, a pharmaceutical setting that could be manipulated for any environment appropriate for emerging technology.

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The Team

POC/VC Programmer

Austin Fritz

UR5 Programmer/Data Analyst

Othul Hock

UR5 Programmer

Abigail Johnstone

UR5 Programmer

Jasmyn Munoz

RoboDK Programmer

Benjamin Nacht

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Background - Pharmaceuticals

Pharmaceutical Industry

1.48 trillion USD in 2022

Responsible for:

Research
Development
Production
Distribution

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Pharmaceutical Packaging

Product protection and accuracy
Demand growth
Expensive process
Inconsistent quality
Resource allocation

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Background - Cobots

Collaborates with humans
Performs repetitive tasks
Versatile functionality
Advantages

Faster reaction time
Exact movement pattern
Capabilities in imitating humans
Safety monitored stop option

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Types of Cobots

Baxter

Rethink Robotics
Two-armed cobot
Designed for simple industrial jobs
Leadthrough programming

UR5

Universal Robots
Medium-duty applications
Payloads up to 11 lbs
Programmed through teaching pendant

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Background - Simulation

Imitation of real-world systems
Exploration of alternatives without real implementation
Can help identify bottlenecks

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iA Pharmaceuticals

Local pharmaceutical fulfillment business
Developed technological solutions

Software-embedded automation technology

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iA Process

SmartPod dispenses medicine into vials
Vials sent to different stations based on order size:

One vial sent to autopack
Two vials sent to semi-auto pack
Three or more sent to manual packing

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Project Focus

Manual Packing Station

Vials manually scanned and placed in SmartShelf if needed
Holds until order is complete
Opportunity of cobotic integration

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iA Smart Technology

SmartShelf

SmartPod

SmartCollator

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Research: Industry 4.0

Fourth Industrial Revolution
Implementation of:

Internet of Things (IoT)
The Cloud
Machine Learning

Enhance Productivity

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Industry 4.0 in Manufacturing

Smart Factories

Sensors
Software
Robotics

Improve decision making
Minimize equipment downtime

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Research: Automation

Software and hardware to create physical product
Overcome human errors and ergonomic challenges
Uses:
Planning
Processing
Assembly
Inspection

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Research: Automation

Industrial Automation/Robots

Repetitive/Dangerous Tasks

Numerically Controlled Machines

Produce parts with few errors through calculations

Flexible Manufacturing Systems

Combine robots and NCMs to adapt to processes

Computer-Aided Manufacturing

Use computers to control entire process

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Research: Cobotics

Collaborates with humans
Performs repetitive tasks
Versatile functionality

Pick and Place
Inspection
Among others

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Research: Cobotics

Advantages

Faster reaction time
Exact movement pattern
Capabilities in imitating humans
Safety monitored stop option

Disadvantages

Not effective for heavy duty applications
Limiting speed
Not suitable for high speed demands

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Research: Cobots in Manufacturing

Can be equipped with camera or sensors that inspect products
Can be used to measure specific components
Precise tool handling
Lower-volume and higher variability

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UR5

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Research: Simulation

Imitating operations of real-world processes

Utilize models

Statistical sampling technique
Mostly used for the purpose of study and analysis
Insight on effectiveness of a system

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Milestones

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Cobot and Simulation Research

RoboDK Simulation

iA Pharmaceutical Research

Visual Components Simulation Model

UR5 Programming

Data Collection and Analysis

Report and Presentation

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RoboDK

Simulation and offline programming tool
Program various types of robots
Simulate NC programs to robot programs

Utilizing G-code or APT-CLS files

RoboDK optimizes the robots path

Avoids singularities, axis limits and collisions

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RoboDK Purpose

Practice robot programming skills
Test pick and place abilities of UR5 cobot
Inspection of objects

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RoboDK Simulation Setup

UR5 Cobot

Two RobotiQ grippers

Table
Inspection machine
Twelve objects

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RoboDK Simulation

First object - picked up by cobot
Object - placed inside inspection machine
Second object - picked up
Cobot takes first object out of machine

Replaces it with the second object

First object - placed back on table

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RoboDK Simulation Video

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Simulation Data

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Total Simulation Time	45.1s
Cycle Time	17.5s
Pick and Place 1st Motion	5.8s
Pick and Place 2nd Motion	3.7s

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Visual Components

Cutting edge software

Production lines
Packaging
Human/robot operators

Built in statistics

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Visual Components

Imitated 2 scenarios
Calculated cycle times

Calculated individual process times first

Basic setup:

UR5
Conveyor
Shelf
Boxes
Human
Stopper
Scanner

Simplifications made

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Scenario 1

Scenario 2

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Scenario 1

Scenario 2

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Scenarios

Scenario 1

Tote 1: Two bottles for Order 1

Placed on shelf

Tote 2: Three bottles for Order 2

Sent to shipping

Tote 3: Two bottles for Order 1

Sent to shipping
Bottles on shelf sent to shipping

Scenario 2

Three bottles on shelf for Order 1
Tote 1: Three bottles for Order 2

Placed on shelf

Tote 2: Two bottles for Order 1

Sent to shipping
Bottles on shelf sent to shipping

Tote 3: Two bottles for Order 2

Sent to shipping
Bottles on shelf sent to shipping

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Scenario 1 Video

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Scenario 2 Video

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VC Process Times

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Process	Average Time
Pick and Scan	5.6 seconds
Neutral to Shelf	2.1 seconds
Shelf to Neutral	2.0 seconds
Neutral to Box	4.7 seconds

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Cycle Time Calculations

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Process	Number	Total (sec)
Pick/Scan	7	39.2
To Shelf	2	4.2
From Shelf	2	4.0
To Box	7	32.9
Total		80.3

Process	Number	Total (sec)
Pick/Scan	7	39.2
To Shelf	3	6.3
From Shelf	6	12.0
To Box	10	47.0
Total		104.5

Scenario 1

Scenario 2

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VC Cycle Times

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Scenario Number	Time to Complete 2 Orders	Average Time/Order
1	80.3 seconds	40.2 seconds
2	104.5 seconds	52.3 seconds

Cycle times do not take into account human motions

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Physical Implementation

Modeled same scenarios in VC and lab
Used videos to calculate cycle time
Helps to consider physical limitations

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UR5 Scenario 1

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UR5 Scenario 2

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UR5 Cycle Times

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Scenario Number	Time to Complete 2 Orders	Average Time/Order
1	118 seconds	59 seconds
2	165 seconds	82.5 seconds

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Differences Between Physical and Simulation

Slightly different movements
Slower base movement speed for UR5
No conveyor belt
Feasibility of cobot implementation by physical means
Numerical and financial analysis based on simulation

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Data Analysis: Cycle Times

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Model	Cycle Time per Order
iA Manual Packing	48 seconds
Visual Components	46 seconds
UR5 w/ Limitations	70.8 seconds

Visual Components data more accurate than real life model

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Data Analysis: Throughput

iA:

1 order / 48 sec =

1 order / 0.8 minute =

1.25 orders / 1 minute

1.25 orders/min * 60 min * 7.5 hours =

562.5 orders/shift

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Data Analysis: Throughput

Visual Components:

1 order / 46 sec =

1 order / 0.76 minute =

1.32 orders / 1 minute

1.32 orders/min * 60 min * 7.5 hours =

594 orders/shift

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Data Analysis: Throughput

UR5 w/ Limitations:

1 order / 70.8 sec =

1 order / 1.18 minute =

0.84 orders / 1 minute

0.84 orders/min * 60 min * 7.5 hours =

381 orders/shift

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Data Analysis: Throughput

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Model	Throughput/Shift
iA Manual Packing	563 Orders
Visual Components	594 Orders
UR5 w/ Limitations	381 Orders

Physically possible for implementation
VC Data proves throughput can be similar to current operations

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Financial Analysis

Factors:

Cost of UR5

$35,000

Cost of RoboTiQ Gripper

$5,000

10 Manual Packing Stations
3 Shifts
Salary of Pharmaceutical Packer

$35,000

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Financial Analysis: Existing Operations Cost

10 operators/shift * 3 shifts = 30 operators

30 operators * $35,000/operator =

$1,050,000

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Financial Analysis: UR5 Operations Cost

$40,000/UR5 * 10 stations = $400,000

$400,000 loan with 4.5% interest = $7,500/month or $90,000/year

5 operators/shift * 3 shifts = 15 operators

(15 operators * $35,000/operator) + $90,000 = $615,000

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Financial Analysis: Results

Existing Operation:

$1,050,000 yearly for 10 operators/shift for 3 shifts

UR5 Implementation:

$400,000 5 year loan at 4.5% interest for 10 UR5s
Only 5 operators/shift required
$615,000 yearly for 5 operators/shift and loan payment
41.4% reduction in operations costs

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Financial Analysis: Results

Existing operations include 30 operators for 3 shifts
UR5 implementation includes $400,000 5 year loan for 10 cobots and 15 operators for 3 shifts

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Existing Operations Expenses	$1,050,000/year
UR5 Implementation Expenses	$615,000/year

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Sensitivity Analysis

Existing Operation:

Cost of labor/shift = ($17)(10 operators)(7.5 hours) = $1275

Cost/Box = $1275/563 boxes = $2.26

UR5 Implementation:

Loan payment/shift = ($90000/year)(1 year/52 weeks)(1 week/40 hours)(7.5 hours/1 shift) = $324

Cost of labor/shift = ($17)(5 operators)(7.5 hours) = $637.5

Cost/box = ($324 + $637.5)/570 boxes = $1.69

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Sensitivity Analysis

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Cost/Box: Existing Operation	$2.26
Cost/Box: UR5 Implementation	$1.69

Cost per Box (Existing Ops) = Labor Cost per Shift ➗ Boxes per Shift

Cost per Box (UR5 Implementation) = (Labor Cost per Shift + Loan Payment per Shift) ➗ Boxes per Shift

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Positive Impact of Project

Reduced cost of non-value added processes

Lower packaging costs
Higher overall throughput

Value of labor
Better data control and accuracy
Less injury risks
Applicable to other industries

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Conclusion

Automation

Reduces mundane tasks for human operators
Effective process delivery
Greater control

Simulation Model and Analysis

Supports implementation of cobot

Human collaboration
Economic viability
Implementation is economically and technically feasible

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Suggested Future Work

Mass implementation

Simulating the entire facility

Management system between humans and cobots
Monitor effectiveness in other industries

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Acknowledgements

Dr. Christopher Greene

Cobot knowledge and experience/advice

iA Pharmaceuticals

Project Manager: Leonard Poch
Graduate Student: Layan Abu-Ghoush

Dr. Sang Won Yoon

Connection with iA Pharmaceuticals

Dr. Mark Poliks

Project guidance and advice

Our ISE Peers

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Thank you!

Any questions?

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