Once workers hear about planned robot integrations at their companies, many begin feeling anxious due to safety concerns. Although robots can malfunction and cause injuries, such incidents are the exception rather than the norm.

Manufacturers build numerous features into their models to keep robots safe around humans. Similarly, those planning to bring robots into the workforce should take several preliminary automation integration steps to prioritize safety. Those elements collectively make it easier to integrate automation safely and effectively, reassuring workers and industrial decision-makers alike.

Listen to Employees’ Robot Integration Concerns

Employees are less likely to worry if they know superiors will hear and alleviate their concerns, so one of the best early steps is to invite teams to give their feedback about stated plans and ask questions. Because workers intimately understand the requirements of their daily tasks, decision-makers can appeal to them by detailing how an automation integration will address some of their most common challenges.

Being open with employees also gives leaders opportunities to hear about the most prevalent worries and address them.

In a 2023 study, researchers found that having employees watch a video of soft robots assisting workers with pick-and-place tasks reduced their concerns about safety or being replaced by the machines. This example also highlights how many workers may be unfamiliar with the robotic advancements that make the machines safer.

Industrial robots once solely worked behind cages that separated them from workers. Many models now feature materials such as fabric and flexible plastics, coupled with speed-limiting mechanisms and sensors, that make the machines recognize humans and slow down if they get too close.

If employees disclose their fears, employers should take those concerns seriously while also informing them about the safety features of the company's robots. This approach helps workers feel heard and realize that their well-being remains at the forefront.

Highlight How Robots Will Lower Current Risks

Automation integration advocates often recommend that industrial leaders focus on the dull, dirty and dangerous tasks when making their investments. Most workers would rather not do these things, and some such tasks risk their lives. The better alternative is for robots to handle those responsibilities when feasible, while humans learn additional skills. They can then continue contributing to their workplaces in a different, more strategic way.

A real-world example comes from a Pennsylvania paper mill that received a robot to clean smelt spouts. Operators who do this without robotic assistance work near molten materials and suffer repetitive motion injuries. However, this task ensures that recovery boilers continue functioning optimally without putting humans at risk.

The plant's robot cleans the spout every half-hour, with each cycle taking 15 minutes. The machine operates within physical safety barriers and has onboard sensors that make it stop if humans bypass those protections. Workers also operate the robot from a control room, allowing them to select cleaning cycles and frequencies. An integrated camera allows technicians to diagnose and troubleshoot problems remotely. This robot integration makes workers safer and gives them time to perform other essential duties.

Keep Workers Involved in Any Automation Integration

Some executives wrongly assume that robots can do everything better than humans, failing to recognize that human workers have accumulated real-world experience that automated technologies cannot match. Keeping safety at the center of a planned robotic integration means continuing to allow employee involvement, even if tasks change slightly due to the automated machines.

Safety risks often arise when systems malfunction, but human supervisors can spot problems early. Having them remain part of the process is a best practice that keeps workers safer and can protect a company's reputation by limiting the consequences of unexpected robot outcomes. The most advanced machines still have occasional issues. Even if those don't threaten employee safety, they could still cause other issues or quality control failures that degrade consumer trust.

Having workers watch as robots operate also minimizes safety-related anxiety. Employees who oversee those machines will become familiar with their built-in features that prevent accidents. Those who recognize the thoughtfulness that manufacturers put into creating safe, productive robots should feel more open to using and being around them.

Emphasize How Robotic Integrations Can Boost Comfort

Many workers, especially those in physically demanding roles, can recall finishing shifts with aching muscles. Although this is a familiar experience, carefully planned robotic integrations make it less common. This benefit also improves safety because fatigue and pain can distract employees, increasing the risk of accidents.

Amazon has integrated robots and other automation technologies into numerous processes. When its engineers design these machines, they look for realistic ways to enhance productivity and worker well-being. Vulcan is one successful example. As Amazon’s first robot with a sense of touch, it can pick and store about 75% of items in the brand's fulfillment centers.

These facilities maximize usable space by keeping products in inventory pods with several compartments, each holding about 10 items. The top row is approximately 8 feet high, so employees had to use stepladders to reach it. Vulcan now handles items at that height, allowing workers to focus on picking and stowing items at the midriff level.

This change provides a more ergonomic option, allowing employees to maintain more stamina and complete more in less time. It also eliminates the possibility of workers falling from heights. Such accidents can have severe consequences, even if the employees are not working at great heights.

Treat an Automation Integration as Potentially Changeable

Besides following best practices for safety, leaders preparing to bring robots into the workplace should remain flexible and realize that they may need to change aspects of previously made plans due to unexpected challenges or worker input. This reality can improve robot integrations, as everyone benefits from executives’ willingness to adapt.

Lou Farrell is the Senior Editor at Revolutionized, and has several years of experience covering cutting-edge topics in the fields of Robotics, AI, and Manufacturing. He enjoys writing more than almost anything else, and has an intense passion for sharing his knowledge with anyone he can.