In today’s industrial environments, automation is no longer a luxury, but a necessity for staying competitive in terms of efficiency, safety, and cost. One of the areas with the greatest potential for improvement is material handling — from moving boxes and parts to feeding machines and palletizing products. However, before integrating a robot into your production line, it’s important to ask a few key questions.
The first step is understanding the exact task you want to automate. What does the operator currently do in that workstation? Is it picking parts and placing them into trays? Moving heavy boxes at the end of the line? Sorting items? Each application has its own specific needs — such as pick-and-place, palletizing and depalletizing, machine loading, or product sorting and packaging. The clearer the task, the easier it will be to find the right technology.
Next, consider what type of robot best fits the task. Not all industrial robots are created equal: some are designed for quick, precise movements with light loads, while others are built to handle heavy lifting or operate in tight spaces. Articulated robots (like those from KUKA or FANUC) are excellent for complex tasks that require a wide range of motion. SCARA robots are great for fast assembly and horizontal movements. Cartesian robots are ideal for linear paths and precise cutting or handling. Delta robots, known for speed, work well with lightweight items in packaging and feeding. And collaborative robots — or cobots — from ABB or Yaskawa are a solid choice when humans and machines need to work safely side by side.
Of course, robots don’t work in isolation. A successful robotic cell includes end-of-arm tools (grippers, vacuum cups, custom claws), vision systems to detect disordered or variably located items, automatic conveyors, sensors, turntables, and controllers to tie everything together. Integrating these components effectively is critical for system performance.
And then there’s integration. The real challenge often isn’t purchasing the robot — it’s making it fit seamlessly into your current workflow. This involves evaluating available floor space, production cycle times, interactions with existing equipment or staff, and links with management software such as ERP or MES platforms. Ideally, this step is supported by a systems integrator who can run simulations or pilot tests before a full rollout.
Safety must also be top of mind. Even robots that seem benign carry risks if not properly contained. This means installing physical barriers or light curtains, proximity sensors, laser scanners, emergency stop buttons, and complying with international standards like ISO 10218 for industrial robots and ISO/TS 15066 for collaborative systems. Safety design should protect both people and machines.
Another important consideration is return on investment. Although the upfront cost of automation — including equipment, installation, engineering, and training — is significant, it can pay off in the medium and long term. ROI is typically seen through reduced labor costs, increased production, fewer errors, and fewer accidents. In many cases, the investment pays for itself within one to three years.
Before launching a full automation project, make sure the solution is technically viable. This means using simulation software like FANUC ROBOGUIDE or ABB RobotStudio, setting up pilot cells, and performing feasibility studies. These steps help optimize key variables before committing major resources.
Finally, think about the impact on your operations. Automation can require rearranging workspaces, retraining existing staff, adjusting shifts, and managing material flows differently. But the upside is that many repetitive, dangerous, or monotonous tasks can be replaced with more efficient processes — allowing your team to focus on high-value work.
Material handling automation isn’t just a technical move — it’s a strategic one. It can transform productivity, safety, and product quality in your plant. But for the project to succeed, you need to start by asking the right questions. Every plant, process, and product is different. Taking time to carefully consider each of these factors is what separates a good automation project from one that truly changes everything.
Automating a process can radically transform your production. At URT, we offer not only high-quality refurbished robots but also personalized technical consulting to support you at every stage of the journey. Contact us today and discover how automation can take your business into the future.