By Chris Pocock, Lead Automation Engineer
When people hear the word automation, they often think about machines replacing manual work. For me, the reality is quite different.
Automation is about giving people better tools, reducing repetitive tasks, improving consistency, and creating safer, more efficient manufacturing environments. That philosophy guided the development of a new collaborative robot, or cobot, workstation for our Large Galvo production line in Stockport, UK.
As Lead Automation Engineer, I joined the team with a mandate to explore opportunities where technology could improve manufacturing processes. The Large Galvo assembly process quickly became a strong candidate. Employees were performing highly precise assembly work involving tiny pins, small screws, and delicate magnetic components that required patience and precision.
Rather than redesign the process entirely, we chose a different approach. We studied the manual assembly process and identified what employees were already doing successfully, building an automated solution around those proven methods. This allowed us to preserve product quality while introducing the benefits of automation.
One particularly challenging aspect involved guiding magnetic components into place without damaging fragile materials. By adapting techniques already used on the production floor, we were able to create an automated process that replicated the success of manual assembly while improving consistency and repeatability.
The resulting workstation combines collaborative robotics, machine vision, automated screwdriving, custom tooling, and intelligent software into a single solution. It is designed to perform repetitive assembly tasks while maintaining flexibility across product variations. Operators simply select the product type, and the system automatically adjusts accordingly.
Beyond productivity gains, the project delivers benefits that matter equally. Reducing repetitive handling of small components helps minimize ergonomic risks. Automated quality checks and controlled assembly parameters improve consistency. Simplified operation also reduces training requirements and supports future scalability.
For me, the most exciting aspect is what this project represents for the future. It demonstrates how manufacturers can combine human expertise with automation rather than viewing them as competing forces. Employees remain essential to the process, providing oversight, knowledge, and problem-solving skills while automation takes on repetitive, precision-based tasks.
As manufacturing continues to evolve, collaborative technologies like cobots will play an increasingly important role. They offer a practical path toward improving quality, safety, efficiency, and adaptability while empowering employees to focus on higher-value work.
This workstation is only the beginning of our automation journey, but it shows what is possible when innovation and practical problem-solving come together to create meaningful improvements.