Industrial robots have been helping humans carry out the three Ds of robotics – “dull, dangerous, and dirty work” – for well over 50 years. Today, advances in smart technology are making manufacturing robots more connected and capable of collaborating with humans to tackle more complex processes.
Physical robots such as robotic arms, cobots, and mobile robotic systems are a central part of modern manufacturing. They often operate within broader automation systems that combine software, controls, and connected machines to coordinate work with reduced human intervention. Together with technologies like AI and advanced analytics, these systems help manufacturers respond faster to changing demand while maintaining high standards for quality, efficiency, and cost.
Robotics in manufacturing refers to the use of programmable machines to perform physical tasks. These tasks are often repetitive, dangerous, or require high precision – such as welding, pick-and-place operations, or assembling complex components. Manufacturing robots come in many forms, including articulated robotic arms, collaborative robots (cobots), and mobile robots, but they all share a common purpose: carrying out physical work with consistent speed and accuracy.
Automation in manufacturing is a broader concept. It describes the overall system that coordinates production activities with minimal human intervention. Automation combines software, control systems, data platforms, and connected equipment – including robots – to manage and optimise manufacturing operations. Increasingly powered by artificial intelligence, modern automation environments use cloud-based platforms, real-time data, and advanced analytics to monitor performance, streamline workflows, and quickly adapt to changing production demands.
In simple terms, robotics is a key component of manufacturing automation. Robots handle the physical tasks on the factory floor, while automation systems connect those machines to production planning, enterprise software, and operational data. Together, they enable manufacturing processes to run more efficiently, respond faster to change, and operate as an integrated system from the shop floor to the business level.
Early manufacturing automation consisted of basic mechanical systems and conveyer belts that moved materials faster. In 1961, GM installed one of the first manufacturing robots, Unimate, to handle die casting and welding. This marked the beginning of modern manufacturing robotics driven largely by the auto industry. These robots excelled at activities that required speed, strength, and precision. The result was increased output, better product quality, and lower costs.
By the early 90s, better sensors and control systems made robots more flexible. Instead of performing one fixed task, robots could support broader manufacturing activities, such as material handling, injection moulding, packaging, and palletising. In the 2000s, robots became more connected to computerised manufacturing systems. This allowed different machines and robotic tools to work together as part of a coordinated production line. As Industry 4.0 gained momentum, technologies like the Industrial Internet of Things (IIoT), cloud platforms, and data analytics helped manufacturers connect equipment and operational data to improve performance.
More recently, integration with ERP and MES platforms has made robotics even more powerful. Modern manufacturing robots can coordinate processes in real time, support automated decisions, and respond to real conditions on the shop floor to improve efficiency across the plant.
While traditional industrial robots were often programmed to perform the same repetitive tasks, today’s robotics systems operate within much more connected environments. In smart factories, robots, equipment, and business systems are linked through IoT sensors and integrated cloud platforms, allowing data to flow between them. Combined with AI and advanced analytics, this connectivity allows robots and production systems to adapt to changing conditions on the fly – such as scaling up production to meet spikes in demand or shifting product lines when materials are scarce.
In some advanced facilities, robotics and automation systems operate with very little human intervention. These “dark factories” can run around the clock without lighting or on-site staff for extended periods. For example, Japanese-based Fanuc manufactures robotics in facilities that operate 24 hours a day for up to 30 days without human assistance. The lights-out Changping Smart Factory in Beijing can produce a smartphone every three seconds with the help of AI technology. While it’s unlikely all manufacturing operations will be fully automated, it’s clear that smart, connected robotics will play an increasingly important role in modern factories.
From fixed to flexible, robots can take many forms depending on the task they are designed to perform. Here are four of the most commonly used robots in today's manufacturing operations – plus one that’s in its early stages of development.
Industrial robots act as the primary robotic support system on production lines today. Perhaps the most well-known is the articulated robotic arm with multiple joints for carrying out complex tasks requiring a range of motion. But there are many others built for different functions. The Cartesian robot, for example, runs on a three-axis system for linear motion and heavy lifting within a defined area. Other robots are built for speed and precision, such as SCARA for tasks like assembly and handling and Delta for pick-and-place operations in high volume environments. Another common robot operates within a cylindrical workspace and combines rotational, vertical, and horizontal motion for machine tending, packaging, and other tasks where a consistent circular motion is needed.
Collaborative robots (or “cobots”) are designed to work safely near humans on factory floors, often sharing the same workspace without the need for safety cages. They can operate autonomously, drawing on computer vision, AI, and machine learning technology to manoeuver around objects and people, but can also be guided or supervised by human operators when needed. Cobots are also more affordable and easier to deploy – which helps explain why the use and development of cobots is on the rise.
As the name suggests, flexible automation systems are made up of robots and automated machines that can be reprogrammed and reconfigured for a wide variety of activities and production runs without having to rebuild the line every time. This makes them ideal for manufacturers that need to quickly switch between product types. Configurable robotic arms that have interchangeable end effectors for welding, pick-and-place, and assembly tasks fit into this category – as well as machine tending cobots that can switch grippers and be programmed to load different sizes and shapes of parts as needed.
These robots are designed to move materials, parts, and finished goods around a factory or warehouse. Take automated guided vehicles (AGVs), for example. These ground-based robots can move pallets, bins, or carts between workstations, usually following a fixed path. Autonomous mobile robots (AMRs) also transport goods and materials on the ground, but they use lidar and ultrasonic sensors, cameras, and navigation software to detect obstacles and reroute around people and equipment. Flying robots are used for activities in high places – no forklifts required. For example, they can scan inventory in high warehouse racks through RFID and barcodes, run safety checks in hazardous or restricted areas, and monitor equipment temperature using thermal cameras.
While still in the experimental stage, humanoid robots are being tested in real production settings. For example, Tesla’s Optimus is a general-purpose humanoid robot designed to support repetitive tasks in the factory. Prototypes in Tesla’s Gigafactories can do simple things like move parts or pick up items. Other humanoid robots like Honda’s ASIMO are used solely for research and demonstration rather than production tasks. Boston Dynamics’ Atlas is also a research and development robot, but is one of the world’s most advanced dynamic humanoid robots built for high mobility, balance, and agility.
AI enhances automation, helping systems adapt to their environment in real time. It can spot patterns in data, trigger actions, flag issues, and even adjust production settings. AI also helps robots recognise parts, avoid collisions, and adapt to changing conditions.
Real-time vision systems use cameras, sensors, and (usually) AI to capture images of any defects, issues, and faulty parts. Manufacturing software analyses the images and sends an alert to operators or stops production accordingly.
The IIoT connects machines, robots, and sensors so they can share real-time data. Sensors track conditions like vibration, output, and energy use – and then send that data to MES, ERP, and other systems to support analytics and automated alerts.
Advanced robotics relies on tight integration with the manufacturing systems that manage work orders, schedules, inventory, production data, and more. Robots and connected equipment use this information and data to coordinate with broader production workflows in real time.
Control systems such as PLCs, SCADA, and industrial controllers manage robotic equipment. They run programmed logic, synchronise production, and automate safety functions. Integration with manufacturing software links robotic operations with business workflows.
Cloud platforms centralise systems, workflows, and data to make automation and robotics work better. They provide scalable storage and computing power to support AI, analytics, and real-time connections. Built-in security and industry-specific processes help speed time to value.
Robotics systems are adding increasing value and efficiency to today’s manufacturing operations. A few of the most common benefits include:
Robots consistently assemble components and place parts on production lines. Robotic arms insert screws or fasten brackets, while cobots snap parts together or load components into fixtures.
Examples: A robotic arm installs bolts on an automotive engine component using consistent torque. In an electronics factory, a cobot places circuit boards into housings and inserts connectors on the line.
Robotic automation systems sort and pick items from conveyors, pack them into boxes, and stack products into stable pallets for storage or shipping.
Examples: An automated pick-and-place system sorts consumer products into cartons based on SKU or order type. Robots pick finished bottles or packaged snacks and load them into boxes for shipment.
Outfitted with cameras, scanners, and sensors, QA robots inspect items as they move through production. Defects such as cracks or labelling errors are identified and rejected immediately.
Examples: In an automotive plant, a vision system inspects welded joints for cracks or gaps. In a pharmaceutical facility, a QA robot checks seals, labels, and pill counts to meet safety standards.
Sensors and connected systems monitor equipment performance and collect data such as vibration, pressure, and cycle times. This supports predictive maintenance, scheduling repairs before breakdowns occur.
Examples: In a chemical plant, pumps and mixers are monitored for leaks. Textile mills track loom tension to reduce defects and maintain consistent output.
Robotic systems track, move, and manage inventory throughout facilities. Automated platforms scan and update stock levels and direct picking and restocking for faster, more accurate fulfilment.
Examples: In a fashion warehouse, robotic systems track SKUs and send alerts as needed. In distribution centres, AMRs move heavy parts and pallets to staging areas.
For decades, robots in manufacturing have symbolised speed, strength, and precision. They were built to do what humans couldn’t – or shouldn’t – do. And while robotics technologies are advancing at a remarkable pace, the real shift lies in how these machines are connected. Robots no longer operate in isolation on the factory floor. Instead, they function as part of a wider digital environment that connects production, planning, quality, and maintenance.
When robotics systems are integrated with enterprise software, connected equipment, and real-time data, manufacturing operations become more predictable and easier to manage. Information flows faster, adjustments happen sooner, and improvements extend beyond a single production line or department. The future of robotics in manufacturing will be shaped not just by the number of machines installed, but by how effectively they work within the connected systems that support modern manufacturing.
Infor’s industrial manufacturing software can help you take full advantage of robotics in manufacturing.