Frequently asked questions

General Questions

What is Robot-Driven Manufacturing?

Robot-Driven Manufacturing with Flexxbotics empowers your robots with the necessary intelligence to command and control automated work and synchronize with other machines, systems and people in the smart factory.

Robot-Driven Manufacturing is the basis of Industry 4.0 “lights out” operations for autonomous manufacturing delivering greater capacity, higher yields, and superior EBITDA profitability. 

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What is Autonomous Process Control?

The ability to achieve six sigma levels of process control for continuous operations without human intervention.

Autonomous Process Control (APC) is the foundational building block of Autonomous Manufacturing. If APC can not be achieved, Autonomous Manufacturing is impossible.

To attain APC consistently requires digitalization using robotic production software that orchestrates factory robots with communication and control of automated machinery. It uses powerful software algorithms to calculate closed-loop feedback adjustments based on the statistical process control (SPC) outputs of test & inspection equipment, vision systems, and sensors to assure the highest levels of precision, accuracy, and quality.

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What Is Advanced Robotic Machine Tending?

Traditional (or basic) robotic machine tending involves having a single robot in front of a machine to handle the repetitive task of loading and unloading parts. 

Sometimes rudimentary custom integration such as an I/O connection is used although the robot does not understand what the machine is doing resulting in unplanned downtime and potential safety issues. These set-ups also lack process integration and coordination with ongoing factory operations.

Advanced Robotic Machine Tending using Flexxbotics connects the robot to factory equipment so the robotic production software can communicate, command, and control the automated machinery for continuous operation, higher throughput, and greater safety.

Advanced robotic machine tending expands the capabilities of basic robot machine tending to enable the robots to operate multi-step operations across multiple machines for a wider range of parts to include different ops such as inspection, sorting, serialization, and assembly all within a single workflow. For example, a robot can load units into several machines, perform secondary operations, automated tests, and then sort and serialize the units.

Sophisticated set-ups will include the ability to update and correct machine programs’ processing instructions (offsets, variables, parameters) based on inspection results to avoid nonconformances, which is called Autonomous Process Control.

If you want to read more on this topic, check out our post on Robot Machine Tending Essentials.

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Why Do We Need Software with Our Robots & Automation Equipment?

Robots come with basic operating software that enables programmatic operation for motion and the ability to execute movement sequences.

The robot’s software however was never designed to enable interoperability with other plant machinery or the coordination of multiple different machines’ operations with its own movements, much less the orchestration of factory-wide fleets of robots running lights out production.

That’s why Flexxbotics exists.

If your plan is to put one robot on a single machine and you’re not worried about unplanned downtime or safety issues, then you probably don’t need Flexxbotics. 

However, if you intend to deploy two, three, five, or more robots in your factory for production purposes, you will quickly figure out that you need Flexxbotics… or you might just give up because it’s hard to scale lots of robots for autonomous operations.

Flexxbotics is for people serious about making production robotic automation work at scale in multi-operation, multi-machine, multi-part type environments to achieve greater levels of manufacturing autonomy.

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Flexxbotics Questions

What does the Flexxbotics solution do?

The Flexxbotics solution is designed for production robotic control, communication, and orchestration of all types of automation machinery, equipment, and IT systems for greater levels of manufacturing autonomy.

Flexxbotics provides a powerful and standardized way to connect and coordinate your production robots with your existing machinery, factory business systems, and people so you can scale robotic automation across your smart factories worldwide.

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What is the breakthrough innovation in Flexxbotics?

At the center of the Flexxbotics solution is our unique breakthrough, the FlexxCORE™ technology, which seamlessly connects and coordinates robots with automation equipment and IT systems. It is patent-pending software infrastructure for robot + multi-machine interoperability and orchestration.

FlexxCORE™  is software-defined automation for software-driven autonomy. It’s a low-code environment for composing and running Transformers, powerful driver connectors. Includes a secure, high performance run-time framework for data pipelines with protocols, class structures, method sets, and data models for development.

Transformers enable bi-directional read/write interoperability between robots and factory equipment for communication, coordination, and closed-loop real time programmatic adjustments.

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What Kinds of Machines Can We Robot-Enable with The Flexxbotics Solution?

Flexxbotics compatibility extends to over a 1000 different makes & models of factory equipment in plants, fabs, and laboratories.

With the Flexxbotics solution, you can robot-enable an incredibly wide range of machines including:

Machining – Mills / Vertical & Horizontal Machining Centers (including 5-Axis), Turning Centers & Lathes, Swiss Lathes, Multi-Tasking machines, and Additive Manufacturing equipment, as well as, a wide range of specialty machines. Additionally, Flexxbotics works with other machines such as Coordinate Measuring Machines (CMMs), CNC Grinders, Deburring equipment, Vertical & Horizontal Honing, Electrical Discharge Machines (EDMs), Brake Presses, Laser Markers & Engravers, and many more.

Semi & Electronics – Automated Test Equipment (ATEs), Automated Optical Inspection (AOI), X-Ray equipment, Tape & Reel machines, as well as, handler systems for Tray Handling, Package Sorting, and other low-payload handler automation. Additionally, add robots to CD-SEMs, Ellipsometers, Automated Die Sorters, Laser Marking machines, Pick-and-Place equipment and for moving FOUPs between stockers and load ports.

Pharma & Biotech – Aseptic Fill-Finish Equipment, Lyophilizers, Vial and Cartridge Capping machines, Autoinjector & Device Assembly machinery, Serialization/Labeling machines, Carton Aggregators, and many laboratory machines such as Centrifuges, Liquid Handlers / Pipetting stations, HPLC/UPLC, Spectrophotometers, PCR Thermal Cyclers, Incubators & Shakers, Freezers, Biorepositories, and others.

The types of machines that the Flexxbotics solution can robot-enable are practically endless.

We obviously don’t have room to list everything here. So, if you don’t see what you are looking for visit our Compatibility page or just ask us here.

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What’s Unique and Different About the Flexxbotics Solution?

Because of the FlexxCORE technology at the center of Flexxbotics solution, robots can connect, communicate, coordinate, command, and control all different types of factory machines in a standardized way for the first time.

Here are three unique aspects only possible using Flexxbotics:

1.) Using Flexxbotics, robots are ‘aware’ of each machine’s processing instructions including real-time status, and have the ability to set and update the machines parameters, variables, and offsets to optimize production.

Benefits:

• Greater throughput capacity
• Reduced downtime
• Increased safety

2.) Integrating closed-loop inspection feedback into the robotic cell with Flexxbotics enables the option for autonomous processing updates based on inspection results.

Benefits:

• Higher quality
• Better yields
• Increased profit per production run

3.) Flexxbotics provides a standardized way to enable robotic automation orchestration of multiple operations across multiple different machines for a wide range of parts or units.

Benefits:

• Longer unattended operation
• Automated change-overs
• Improved utilization

These are only a few of the differences that only Flexxbotics includes. There are numerous other autonomous manufacturing benefits that Flexxbotics breakthrough capabilities enable such as faster set-ups, increased unattended operation, improved machine-to-labor ratios (typically greater than 20 : 1), and ultimately higher margins with “lights out” production.

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Does Flexxbotics Make Robotic Machine Tending Safer?

Yes. Flexxbotics further enhances the safety capabilities of robotics automation scenarios. Our solution includes safety scanner capabilities for enhanced motion detection enabling people to work even more safely with the robots in smart factory environments.

Flexxbotics bi-directional communication between the robots and the machines is also a significant safety enhancing factor. Direct communication to each machine’s controller provides multiple layers of safety redundancy to ensure the right actions are being taken or not taken.

Flexxbotics makes the robots aware of each machine’s processing instructions including real-time status. For example, Flexxbotics ensures that each part is fixtured or seated correctly and that any enclosure or auto-door on the equipment is closed before initiating a cycle-start.

With custom third-party PLC integrations and I/O tie-ins, your shop floor personnel can be exposed to robot/machine safety issues due to a lack of coordination meaning your company assumes unnecessary liability risk.

Flexxbotics delivers the highest safety levels possible in robotic production. With Flexxbotics the robots are instructing the machines to perform operations taking into account human safety and assuring that the automation is not in an unsafe position before initiating an action. 

Flexxbotics also offers safety and risk assessment to ISO 10218, ISO/TS 15066 and other compliance requirements as an option with our implementation services.

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What Is Flexxbotics Intelligent Recovery™ Capability?

Flexxbotics has introduced a first-of-its-kind new option called Intelligent Recovery™ which enables collaborative robots to recover autonomously from non-safety related work-stop situations.

During operation, collaborative robots periodically encounter circumstances which cause the robot to stop and then require a human to reset and restart. 

These occurrences, such as part-workholding contact and other non-safety related conditions, lead to unplanned downtime and can cause substantial reductions in utilization and production output. 

Now, with the Intelligent Recovery™ option, Flexxbotics enables robotic automation to recognize its context and automatically recover so manufacturing continues without downtime or human intervention.

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Does Flexxbotics Work on Our Mobile Devices Like Tablets, Laptops and Smartphones?

Yes. Flexxbotics includes secure access to mobile-enabled functionality with progressive web application capabilities. 

With Flexxbotics, manufacturing executives can see automated production as it occurs in factories around the world from phones and tablets anywhere. Trend data and dashboard visibility provide real-time status with output and quality metrics. 

Downtime alerts and escalations can be either text messages, email notifications or both with clickable links to go straight to the issue. 

Flexxbotics works on all Windows, iOS and Android devices including ruggedized smart devices.

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Does The Flexxbotics Solution Include Both Software and Hardware?

Yes. The Flexxbotics solution includes robotic production software for connecting multiple robots and machines, as well as, digital control room dashboards, analytics & reporting, alerts & escalations, smart workflows, file control, and a lot more. 

In addition, the Flexxbotics solution includes the option for an automation console with edge device hardware and machine interface connectors including Ethernet ports, M12 DIO connectors, and USB to simplify the connection of robots with machines.

Flexxbotics can be connected to most controllers with a single Ethernet cable.

Basically, the Flexxbotics solution provides exactly what you need for robot + multi-machine interfacing and operation across your smart factory at scale.

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Does The Flexxbotics Solution Require Us to Purchase Any Additional Hardware or Machinery?

Simple answer is that depends on what you’re trying to accomplish and what equipment you have already.

The Flexxbotics solution includes as many edge device hardware units with machine interface connectors as your installation requires as part of your Flexxbotics package.

In addition, we offer the option to purchase other hardware you may require – depending on your robotic automation project’s requirements – either directly from Flexxbotics or from your provider of choice.

Examples include collaborative robots / cobots or industrial robots, grippers, fingers and other end of arm tooling (EOAT), in-feed / out-feed part presentation shelving racks, trays, carts, auto-doors, blow-off system, vision systems, laser safety scanners, light curtains, and other equipment depending on the nature of your project.

Our experts assist in helping you define and design everything needed for success during a discovery workshop to ensure your project requirements are met including any hardware needs.

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Does Flexxbotics Require Other Software That We Will Have to Buy?

No. Flexxbotics provides all the software required to run the Flexxbotics solution.

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Does Flexxbotics Work with Existing It Business Systems?

Yes. Flexxbotics is specifically designed to connect to existing IT systems.

Just to be clear, you don’t need any other software / IT system to run the Flexxbotics solution.

Flexxbotics is a modern web architecture with full API capabilities for bi-directional integration with ERP/MRPs, MES, QMS, DNCs, CAD/CAM, SCADA/HMI, IIoT, PLM/PDM systems, as well as, your own custom systems. 

Your company’s specific requirements and existing systems determine the appropriate connector options.

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Do We Have to Replace Any of Our Existing It Systems in Order to Use the Flexxbotics Solution?

No.

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How Much Does Flexxbotics Cost?

Flexxbotics has a range of software packages and service offerings depending on your robotic automation project complexity and business needs.

For a turnkey automation cell project the total costs can range from $120,000 to around $300,000 depending on the complexity of the project for all aspects including services, hardware, and the Flexxbotics solution.

The Flexxbotics packages include volume discounts for factory-wide and multi-factory enterprise implementations.

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What Professional Services Does Flexxbotics Offer?

Flexxbotics understands how to augment your staff’s skill levels and work with your team to bring together the physical and digital worlds. Our experts provide a full range of professional services for the Flexxbotics solution to ensure successful deployment and optimized operation.

Whether rolling out the Flexxbotics solution across a multi-site smart factory environment or a single robotic cell, the Flexxbotics team provides comprehensive deployment options to fit any strategic automation roadmap.

Flexxbotics offers turn-key deployment options for our automation solution to help you realize your digital robotic production goals. We work with your team to ensure success and achieve measurable business results on an ongoing basis.

Flexxbotics service options include:

Automation Planning Sessions

• Requirements Discovery Workshop
• Automation Selection Discovery Workshop
• Automation Roadmap Discovery Workshop

Automation Enablement Design Services

• Automation Cell Layout
• Component Selection
• Part Presentation Infeed / Outfeed Design
• Workholding / Fixturing Requirements
• Gripper Fingers / End of Arm Tooling Definition
• Secondary Operation Layout & Set-up
• Deburring
• Washdown / Cleaning
• Blow-Off
• Safety Design Services

Automation Cell Implementation

• Hardware Installation and Configuration
• Robot programming
• Machine Interfacing
• In-Line Inspection Installation and Configuration
• Factory Acceptance Testing / Site Acceptance Testing
• Safety & Risk Assessments
• Production Run-off & Optimization
• Business IT Systems Integration

Training

• Flexxbotics Solution Training
• Manufacturing Engineer Training
• Operator Train the Trainer
• Operator Automation Training
• Custom Training for Specific Requirements

Support

• On-site & remote support options
• 10/5, 24/5 and 24/7 support options
• Weekly performance reports
• Optimization Reviews
• Troubleshooting & Resolution

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How Quickly Can We Anticipate a Return on Investment (ROI) With Flexxbotics?

Most robotic automation projects using Flexxbotics achieve a positive Return On Investment (ROI) in less than a year and many in under 9 months.

As part of our automation planning sessions, we provide ROI calculations that you can use for CapEx justification.

ROI can include Capacity increases, Labor savings, Safety, and Yield improvement as well as other considerations. The scope, scale and complexity of your initiative will determine the necessary factors required to determine exact calculations and timeframe for positive returns.

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Can We Deploy Flexxbotics Factory-Wide?

Yes. The Flexxbotics solution can be implemented in multiple factories at scale, a single factory, or individual automation cells one-by-one to avoid manufacturing interruptions, risk, and disruption.

In addition, Flexxbotics professionals provide turn-key services for the Flexxbotics solution to ensure successful deployment and optimized operation.

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Can We Install Flexxbotics on A Single CNC Machine?

Yes. The Flexxbotics solution can be deployed on one machine or a single automation cell.

You can start with one cell, get results quickly, and build on success incrementally to scale out automation across your entire factory… or just run your one robot all the time.

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Robotic Operation Questions

Can I Re-Deploy Robots Using Flexxbotics?

Yes. Flexxbotics enables robots to be re-deployed to other machines in the factory.

Keep in mind that robot re-deployment may require different in-feed/out-feed, end-of-arm tooling, or other considerations depending on the new machine and new operations you’ll be running, as well as, the new part mix being processed.

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What Is a Robot Reference Frame?

Robots are generally programmed relative to their base. This means every waypoint and move is taught relative to the base. 

If you move the robot’s base, your robot’s movements and waypoints will move proportional to the distance the base has moved. You can use alternate frames such as reference points. 

These reference points give what are called real-world coordinates to a robot so it can have a better understanding of its location.

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What Is the Accuracy of Providing a Stationary Reference?

Flexxbotics has figured out how to provide the robot with a stationary reference point for easy calibration. There are two accuracy versions. 

The standard version has an accuracy spec of +/- 1mm from the TCP. The High Accuracy version has an accuracy spec of +/-0.1- 0.5mm from the TCP. The High Accuracy spec is based off a normal distribution with the median being 0.3mm and a standard deviation of 0.1mm.

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Do I Need to Put the Robot in The Same Place When Using the A Stationary Reference?

The simple answer is No. Our stationary reference uses hardware and software to offset your program without the need to dock your robot. 

If your robot is mobile, we suggest that you put some markers on the floor to place the wheels of your robot in a relatively similar spot for consistent robot waypoint reach.

We also suggest using the align feature of our Flexxbotics reference tool which creates a waypoint for your robot to go to about 6 inches above your lockout point. This assists your operator with locating a relatively close location to where the robot needs to be positioned.

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How Do I Know Which Flexxbotics Feature to Update for Each Program?

Flexxbotics features are saved in two locations in the robot’s orientation system. You can find Flexxbotics features in the Installation tab and on the Flexxbotics Toolbar. 

Any Flexxbotics Features you create will be populated in both areas.

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How Do I Activate My Flexxbotics License?

Simply input your unique license key after you have downloaded the associated Flexxbotics extension for your robot or machine, for example, a URCap software extension. 

The extension software will also be located on a Flexxbotics labeled USB. If you have not been provided the appropriate extension or license key please reach out to support@flexxbotics.com

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What Applications Are Best Suited for Flexxbotics?

Flexxbotics is not an application specific solution. We focus on production robotic process automation enablement.

The types of manufacturing that typically benefit the most from the Flexxbotics solution include next generation automated manufacturing environments, high mix scenarios, multiple SKU conditions, manual-to-automated station changeover.

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What Is a Robot Offset?

A robot offset is a software adjustment made to a robot’s waypoints and moves. It takes the kinematic difference between a robot’s original and new position and updates the moves and waypoints relative to that kinematic difference.

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How Many Degrees of Freedom Does the Flexxbotics Offset Provide?

The Flexxbotics offsets a program’s moves and waypoints in 6 degrees of freedom or X,Y,Z, Rx (Roll), Ry (Pitch) and Rz (Yaw).

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If My Operator’s Don’t Have Access to The Program and Installation Tabs Can They Still Utilize Flexxbotics?

Yes. We have specifically designed capabilities to address this issue. Configurable command buttons can operate all production functionality of the Flexxbotics solution

The command buttons have been designed to be as intuitive as possible allowing any skill level operator with secure access to utilize the Flexxbotics solution.

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What Is the Difference Between a Vision Offset and a Flexxbotics Offset?

Vision offsets use a vision system, 2D barcodes or markers and software to provide an offset to a robot. 

The vision system needs to set a specific angle and distance to be captured correctly. Mechanical offsets such as Flexxbotics use a locking mechanism and software to provide a highly accurate offset that works in all different types of environments.

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How Should I Physically Move My Robot Around?

We suggest using a mobile industrial robot (MiR) or mobile cart that is proportional to your robot’s size. Flexxbotics can provide mobility options that optimize center of mass and angular acceleration analysis taking into consideration force so your robot will not move once the wheels are locked in place. We can help you define your project’s specific requirements or you can provide them directly.

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What Is the Difference Between Robot Utilization, Efficiency And Capacity?

Robot utilization, capacity and efficiency are the three most important metrics for your robot and are all interconnected. 

Robot Capacity is the maximum amount of time a robot can run. If you have three eight hour shifts the robot has a total capacity of 24 hours.

Robot Utilization is the amount of time a robot is running vs the robot capacity. If a robot runs 22 hours with a total capacity of 24 hours it has a utilization rate of 91.7%.

Robot Efficiency is the part output vs time vs yield. If a robot makes 805 parts in 8 hours and 800 of those parts are accepted then it has an efficiency of 100 parts per hour.

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