Cost-Reduction Strategies in Robotics and Automation

Cost-Reduction Strategies in Robotics and Automation

For businesses—especially small and medium-sized manufacturers—lowering costs in robotics and automation is crucial for maintaining competitiveness. Below are 12 proven strategies to reduce expenses while maximizing efficiency in robotic automation, with a focus on robot arm applications.

1. Choose Refurbished Robot Arms

Purchasing refurbished robot arms instead of new ones can significantly cut costs without sacrificing performance. Many suppliers restore used robot arms to like-new condition, offering warranties and reliability at a fraction of the price.

Key Benefits:

• Cost savings of 30-50% compared to new robot arms.

• Tested and recalibrated for optimal performance.

• Ideal for businesses with budget constraints.

2. Start with Collaborative Robot Arms (Cobots)

Collaborative robot arms (cobots) are an affordable entry point into automation. Unlike traditional robot arms, cobots are designed to work alongside humans, require minimal programming, and are easy to deploy.

Why Cobots?

• Lower upfront costs than industrial robot arms.

• No need for safety cages in many applications.

• Simple programming via hand-guiding or intuitive software.

3. Automate Key Repetitive Tasks

Instead of automating entire production lines, focus on high-impact tasks where robot arms provide the best ROI.

Examples:

• Pick-and-place operations.

• Assembly line tasks.

• Material handling and packaging.

Result: Faster payback period and reduced labor costs.

4. Use Modular Robot Arm Systems

Modular robot arms allow customization and future upgrades, eliminating the need for complete system replacements.

Advantages:

• Scalability – Add or modify components as needed.

• Cost-effective upgrades – Avoid buying new robot arms for minor changes.

• Flexibility – Adapt to different tasks with minimal reconfiguration.

5. Invest in Preventive Robot Arm Maintenance

Regular maintenance extends the lifespan of robot arms and prevents costly breakdowns.

Maintenance Tips:

• Lubricate joints and check wear parts.

• Calibrate sensors and actuators periodically.

• Monitor performance to detect early signs of failure.

Outcome: Fewer unplanned downtimes and lower repair costs.

6. Consider Robotics as a Service (RaaS)

Instead of purchasing robot arms outright, Robotics as a Service (RaaS) allows businesses to pay for automation on a subscription or usage basis.

Benefits:

• No large upfront investment in robot arms.

• Flexible scaling – Adjust automation as needed.

• Includes maintenance and updates from the provider.

7. Select the Right Robot Arm for the Task

Not all robot arms are equal—choosing the wrong one leads to unnecessary expenses.

Selection Criteria:

• Payload capacity – Avoid over-specifying.

• Reach and speed – Match to application needs.

• End-of-arm tooling (EOAT) – Use cost-effective grippers.

Result: Avoid overspending on excessive capabilities.

8. Reduce Integration Costs with Expert Partners

Robot arm integration can be expensive, but working with experienced system integrators helps minimize costs.

How?

• Optimize cell layout for efficiency.

• Use standardized interfaces to reduce custom programming.

• Leverage existing infrastructure where possible.

9. Use Simulation Software Before Deployment

Simulating robot arm operations before physical implementation prevents costly errors.

Simulation Benefits:

• Test workflows virtually to optimize performance.

• Identify collisions or inefficiencies early.

• Reduce downtime during real-world deployment.

10. Train Employees for In-House Expertise

Relying on external specialists for robot arm programming and maintenance is expensive.

Solution:

• Internal training programs for operators and technicians.

• Cross-training to handle multiple robot arm models.

• Reduce dependency on third-party support.

11. Implement Simple Automation Where Possible

Not every task requires advanced robot arms—sometimes, basic automation suffices.

Examples:

• Fixed automation for single repetitive tasks.

• Pneumatic systems for lightweight handling.

• Low-cost grippers instead of complex EOAT.

Outcome: Lower initial investment and faster ROI.

12. Adopt Predictive Maintenance for Robot Arms

Using IoT sensors and AI-driven analytics, predictive maintenance helps avoid unexpected robot arm failures.

How It Works:

• Monitor vibrations, temperature, and wear.

• Predict failures before they occur.

• Schedule maintenance proactively.

Result: Increased uptime and lower repair costs.

Conclusion

By implementing these cost-saving strategies, businesses can effectively integrate robot arms and automation without overspending. Whether through refurbished robot arms, cobots, modular systems, or predictive maintenance, each approach contributes to a more affordable and efficient automation solution.

Final Tip: Always evaluate the total cost of ownership (TCO)—not just the initial price—when investing in robot arms and automation.