KUKA, the Circular Economy and repurposing robots

KUKA UK has recently taken a number of KR 250’s and KR 500’s in for refurbishment from a major automotive customer. They’ll undergo a significant schedule of renovation under the care of our accomplished customer service engineers at KUKA, Wednesbury, in preparation for redelivery as 2nd life automation assets at the busy plant.

Some of the works being undertaken include, but are not limited to: A full inspection and condition report; PC upgrades including hardware and software to the latest KSS8.6; Full maintenance; New RDC (resolver digital converter); New energy supplies; New floor mounting plates\bolts\dowels; New Paint Job & KRC4 cabinet clean.

The shift toward a more resource-efficient way of delivering modern technologies and automation to our customers is integral to our sustainability strategy, which aligns with circular economic principles: existing materials and products are repaired, recycled or repurposed for as long as possible, extending the?life cycle of our robots.

“Our automation solutions are made to be as durable as possible, to save on valuable resources, but to also deliver a level of reliability, solution longevity and maximum productivity to our customers,” says Steve Hudson, Customer Services Manager, KUKA UK & Ireland. “By refurbishing established hardware, we aim to save costs and resources that are associated with purchasing new robots. The KUKA industrial robots are designed to offer the longest possible maintenance intervals, at 20,000 hours, no matter what the work sequences, or payload. However, some extreme or hazardous environments can impact that, and we aim to mitigate any failures through proactive maintenance and refurbishment programmes.”

Manufacturing today is becoming more environmentally astute, and robotics and automation are addressing many of the challenges that have arisen in recent times, borne from a demand for sustainable products. Such as reductions in waste, raw material usage, cost savings and customisation. Processes such as additive manufacturing, or 3D printing can now be delivered at large scales, using industrial robots. Labour shortages are being mitigated through the utilisation of automated processes, sustaining localised supply chains thus reducing imports and carbon emissions. Accuracy and repeatability of application delivery eliminate errors and potential costly recalls. ?

Consumers are more aware of the green credentials of suppliers, and assurances of sustainability conscientiousness are driving engagement. KUKA, for example, offers the responsible disposal or recycling of used robots. The steel and aluminium used by KUKA generally have a high recycling content. This?conserves valuable resources?- and also makes economic sense.?

Used robots?expand the KUKA range, and this offer is well received. For example, used machines offer smaller companies a good and inexpensive entry into automation. And other customers want to reuse tried and tested equipment in a large system. A similar process to that illustrated in the engineering & maintenance project referenced above, to return refurbished KR 250 & KR 500 robots to active duty, is undertaken, complete with warranty.

The Automotive industry is the UK’s largest manufacturing sector, closely followed by the Food & Beverage industry. The industry is diversifying, and manufacturing models are becoming more dynamic as we enter the age of e-mobility. Electric vehicles are set to decarbonise the planet and as combustion engine manufacture makes way for battery production, on masse. Process chains are diversifying too, though one thing is clear, robots and automation shall continue to form an integral part of the process, as resource-efficient production tools.

“There has been a huge shift in attitudes lately. ‘Take-make-waste’ is no longer acceptable. UK manufacturers must be seen to be keeping products and materials in use for as long as possible” says Hudson “Preserving the value of ‘things’, designing for use longevity and legislating for circular systems is of paramount importance”. He adds “Take the KR QUANTEC for example, which has a reduced number of components thanks to its modular design. Or the KR IONTEC that is sustainably cost-efficient, thanks to its low energy consumption.”

KUKA’s refurbished machines leave our facility as good as the day they were manufactured, both robots and control cabinets. It’s a far cry from decades past, when to simply order a new robot was standard procedure, without thought for how that which was surplus to requirements might have been dealt with.

As part of the customer service offering delivered out of our UK and Ireland facilities, refurbished spare parts are also available. Items that have been professionally reconditioned and are available at a fraction of the cost, with a warranty, further substantiating our commitment to refurbishing and recycling existing materials.

Steve concludes “We are at the centre of the digital transformation. We see it as our responsibility to contribute to a sustainable future, through mitigation of waste of repurposing of materials, wherever possible.”