Caught between higher costs, smaller runs and distance from global markets, ANZ manufacturers must work smarter to compete, survive and thrive. With agile robots, sensors and software now more accessible than ever, learn how these Aussie makers punch above their weight on the world stage.
Adaptable automation required a fundamental shift in technology that has been decades in the making. The first breakthrough came in the 1990s when affordable computers, sensors and servo-drives finally converged, making flexible automation not just possible, but practical.
Today, simple programmable robots have matured into an integrated suite of technologies uniquely suited to Australia’s challenging manufacturing landscape.
For decades, manufacturing automation was built on fixed systems perfect for mass production, but not economically viable when producing low volumes or custom product variations, leaving Australian manufacturers in a tough spot, with:
The emergence of adaptive automation changed everything, enabling rapid reconfiguration through software updates rather than mechanical retooling.
“It’s not about replacing human labour. It’s about reimagining the entire manufacturing process to create competitive advantages through adaptability,” explains Dr Wong.
The payoff for manufacturers is significant: faster changeovers, economic small-batch production and the ability to produce customised products at competitive prices.
Walk into advanced Australian factories today and you’ll see four key technologies working together to create manufacturing environments that can pivot as quickly as the market demands:
Supporting this growth will require a steady supply of high-quality talent. While Australia boasts some fine institutions turning out excellent graduates, the Strategy Paper missed the opportunity to turn the spotlight on education partnerships with industry. Applied Robotics is doing its part by investing in local talent through comprehensive training and development programs. Countries with strong industry-academia collaborations are often more competitive globally due to a robust innovation ecosystem. Educational partnerships in Australia may not be attractive as they do not appear to be beneficial to industry. The Strategy Paper could have looked at co-investments and government funding to take these partnerships to the next level.
Australia can also better leverage its successes in applying robotics solutions. No doubt, Wi-Fi and Cochlear are great Australian innovations but it will be beneficial to do a deep dive into the country’s recent successes in applying robotics solutions particularly in the areas of mining and farming. Robotics solutions typically require significant investment and showcasing Australia’s proven capabilities will encourage more organisations to commit to the journey.
Without a doubt, the National Robotics Strategy is a welcome first step as it turns the spotlight on to a key aspect that is critical to nation building. Applied Robotics is calling on the government to join industry in a “whatever it takes approach” and move the National Robotics Strategy from a document to a national priority.
At the heart of this revolution are machines that move with purpose and precision:
“The global adoption of industrial robots has dramatically reduced costs while increasing capabilities,” explains Dr Wong.
“With 4.3 million industrial robots installed worldwide as of 2023, up from 1.3 million in 2013, these technologies are mature, reliable and more accessible than ever. While China leads with 250,000 installations, Australia has only about 8,000 units – showing significant opportunity for growth.”
Beyond robots, intelligent transport and gripper systems create factory-wide coordination:
This integration creates what Dr Wong describes as ’a dance of coordinated movement’ where products flow smoothly through production without the rigid infrastructure of traditional automation.
The ability to perceive and adapt to variations makes all the difference:
Capral Aluminium’s packing system shows these technologies in action. Their system utilises advanced 3D cameras to identify over 6,000 unique aluminium profiles – even with notoriously difficult reflective surfaces – and then determines optimal picking and packing strategies on the fly.
Manufacturing Execution Systems (MES) and other advanced software – once only affordable for large enterprises – now act as the affordable, cloud-based brains behind the operation, tying everything together:
“When we deployed Australia’s first AI-based factory automation system for Capral in 2018, the intelligent algorithm could identify, grasp and nest each unique extrusion shape in real-time – something impossible with traditional automation.
This concept was also central to Arnott’s revolutionary biscuit assortment system, which precisely processes up to 105 biscuits per second,” explains Dr Wong.
When Legrand Australia needed to maintain local light switch manufacturing in the face of offshore competition, they turned to adaptive automation. We designed a system that handles configurations from single switches to six-gang units with minimal changeover time, doubling production output while simultaneously reducing labour requirements.
Macnaught’s semi-autonomous assembly solution demonstrates how Australian manufacturers can make smaller runs profitable. The system handles over 110 SKUs of industrial equipment while doubling production rates – precisely the flexibility required to meet Australia’s diverse market demands.
“When products can’t be produced cost-effectively locally, they inevitably move offshore. Adaptive automation helps Australian manufacturers compete on factors beyond just labour cost – enabling some operations to be brought back onshore,” notes Dr Wong
Unlike fixed automation, which becomes obsolete when products change, modern systems can be reprogrammed to meet new requirements, protecting capital investments over the long term.
The results speak for themselves.
Capral Aluminium’s implementation of AI-powered robotic packing slashed freight volumes by 50% while accelerating distribution and improving quality.
What’s remarkable is that this was achieved while handling an ever-changing range of 6,000 unique profiles with customisations – precisely the kind of challenging environment where traditional automation would fail.
At an Australian audio technology manufacturer, our innovative assembly system achieved a 95% first-pass success rate, reducing the number of operators required from 2-3 to a single operator.
Look beyond individual machines to the entire process flow. Consider how materials, information and finished products move through your operation. The most elegant solution for one department might create bottlenecks elsewhere.
Successful implementations require meticulous attention to specifications, edge cases and integration points. These can make or break commercial success over time. Rigorous testing and validation before implementation aren’t optional luxuries – they’re essential investments.
Every successful automation project needs a dedicated leader who can bridge technical and business perspectives while driving the project to completion. Without this champion, even the best technology can falter.
“The planning phase has the most influence on final results. The most brilliant project management or technology solution cannot overcome a poorly conceived business case,” explains Dr Wong.
For Australian manufacturing, success isn’t about competing on volume – it’s about leveraging adaptive technologies to create competitive advantages through flexibility, quality and innovation.
Adaptive automation breathes new life into the local industry with systems that adapt as quickly as market demands change, turning traditional disadvantages into our greatest strengths. And the transformation is just beginning.
To explore flexible automation solutions for your manufacturing operations, contact our expert team for a discussion
