Automation has been a key driver in the evolution of the manufacturing industry, and in the pharmaceutical sector, this trend is reaching new heights thanks to collaborative robots, or “cobots.” The Takeda plant in Oranienburg, Germany, is a clear example of how technology can alleviate both the physical problems of workers and improve overall productivity. With the installation of a FANUC CR-15iA cobot, this pharmaceutical factory has managed to transform one of its most demanding tasks, such as the packaging of medicines, into a much more efficient and less risky process for its employees.
Workload Involving Workers’ Health
Before the introduction of the collaborative robot, Takeda employees had to move heavy loads totaling 5.8 tons per shift. This constant physical effort caused numerous sick days, affecting workers’ morale and the plant’s efficiency. Long shifts and manual handling of heavy products affected the health of the operators, so the pharmaceutical company began to seek solutions to lighten this physical load without compromising quality or productivity.
The Cobot Solution: Technology and Human Collaboration
The answer came from FANUC, a leader in automation solutions, with its CR-15iA model, a cobot specifically designed to work closely with humans. This robot, along with the system integrator SKDK, has taken charge of a critical part of the production process: stacking boxes of medicines on pallets for shipping. The cobot takes the boxes from the production line, scans their labels, and stacks them in precise configurations, 8 boxes per layer and 4 layers high. With a load capacity of up to 15 kg and a reach of 1,441 mm, the robot can work 24 hours a day, 7 days a week, without needing breaks, significantly reducing the physical effort for operators.
Collaboration, Not Replacement
One of Takeda’s main goals in integrating this cobot into its plant was to ensure that employees did not feel their jobs were being replaced by machines. From the start, the company promoted a collaborative approach, involving workers in the implementation process. Through informational events, operators were explained that the robot was not a threat to their jobs but a tool to facilitate their daily tasks. Takeda’s approach was to present the cobot as a “new colleague” that would work alongside them, alleviating the weight of physical loads and allowing employees to focus on more complex tasks.
The introduction of the cobot has also been easier thanks to the nature of the CR-15iA, which does not need to be enclosed in a safety cage. Its design allows workers to approach it without fear of accidents, which has improved acceptance of the technology and reduced initial operator reservations. According to Sebastian Steinbach of FANUC, this design was key to the implementation’s success, as people could interact more closely and naturally with the machine.
Compliance with Hygiene Standards and Tangible Results
In a pharmaceutical environment, hygiene is a fundamental factor. The FANUC cobot meets strict cleanliness standards, with extra smooth surfaces that minimize dust and dirt accumulation. Additionally, its IP67 protection on the arm and wrist axis ensures it can operate in high hygiene conditions without compromising performance.
Since its installation, the system has processed thousands of packages without incident, and productivity has improved significantly. Not only has the physical burden on workers been relieved, but efficiency levels have also increased, and sick leaves have decreased. This success has led Takeda to consider expanding the use of collaborative robots in other areas of the plant and its other facilities globally.
A Collaborative Future
The Oranienburg plant has served as a reference model for Takeda and other companies within the pharmaceutical industry. With the installation of the CR-15iA cobot, the company has shown that automation not only improves efficiency but also takes care of employees’ well-being. As more Takeda plants begin to evaluate similar projects, the future of the pharmaceutical industry seems increasingly focused on human-robot collaboration, an alliance that promises to improve both work-life quality and business outcomes.
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