How process-first engineering turns automation into a manufacturing advantage
By Jeff Metz
Automation Has Evolved, and So Have Expectations
When people hear the word automation, they often picture a robot performing a single repetitive task behind safety fencing. While that image still exists, it no longer reflects how modern manufacturing leaders think about automation.
Today, automation is less about installing a robot and more about designing a complete system around a real production process, one that accounts for parts, people, safety, space, data, and long-term scalability.
That philosophy is at the heart of Yaskawa Motoman’s approach to custom automation. It’s also the central idea behind the recent “Not Just Robots” webinar: automation works best when it’s engineered around how a product is actually made, not forced into a one-size-fits-all solution.
What “Custom Automation” Really Means
Custom automation is often misunderstood as something reserved only for massive, high-budget projects. In reality, custom automation can range from small, highly focused systems to large, multi-million-dollar production lines.
At Yaskawa, custom automation typically means:
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Integration of robots, tooling, vision, controls, and safety systems
The goal isn’t simply to automate, it’s to improve the way a product is made, whether that improvement comes from higher throughput, improved weld quality, reduced ergonomic risk, or increased production flexibility.
Why Process Comes First
Before a robot is selected or a layout is drawn, the most important work happens upfront: understanding the process.
Every custom automation project begins with questions such as:
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What defines success, cycle time, quality, labor savings, or flexibility?
Understanding the current-state process is critical. In many cases, the best solution is not to completely reinvent production, but to replicate and enhance what already works using automation.
This process-first mindset helps avoid common pitfalls, such as automating unnecessary steps or designing systems that look impressive but fail to deliver meaningful ROI.
From Data Collection to Concept Development
Once requirements are defined, engineering work begins in earnest.
Application engineers develop concepts using 2D and 3D layouts, reach studies, and simulation tools. These early models answer fundamental questions:
Cycle time analysis plays a major role at this stage. It helps determine system size, robot count, and overall feasibility—ensuring the solution aligns with the customer’s return-on-investment expectations.
Tooling, Vision, and Safety Are Not Afterthoughts
In a true turnkey system, tooling, vision, and safety are engineered alongside the robot—not added later.
Tooling
Tooling decisions consider:
Custom fixtures may include mechanical clamps, compliance devices, vacuum solutions, or quick-change tooling depending on the application.
Vision Systems
Vision plays a growing role in modern automation, enabling:
Vision partners work closely with engineering teams to select the right camera and sensing technology for each application.
Safety
Safety is integrated throughout the design process. Systems are engineered to comply with:
Safety solutions may include functional safety units, scanners, light curtains, and interlocks, often aligned with customer-preferred brands.
Flexible Building Blocks: Standard, Modified, and Custom
Not every automation project starts from scratch. Many solutions combine standard products with customized elements.
Yaskawa automation systems generally fall into three categories:
This flexibility allows manufacturers to balance speed, cost, and customization while still achieving a tailored result.
Coordinated Motion: When the System Becomes the Advantage
One hallmark of advanced automation is coordinated motion—where robots and external axes move together as a single system.
Modern controllers can coordinate:
This capability is especially valuable in applications such as arc welding, where maintaining optimal weld position improves quality and consistency.
By rotating or repositioning the part while welding, coordinated motion enables:
Beyond Welding: Automation Across Industries
While robotic welding remains a core strength, custom automation extends far beyond a single process.
Examples highlighted during the webinar include:
Each solution reflects a common theme: the system is engineered around the product, not the other way around.
The Role of the Advanced Systems Group
Delivering these solutions requires more than robots—it requires deep experience.
Yaskawa’s Advanced Systems Group (ASG) brings together:
This integrated structure ensures continuity from concept through installation, with a single point of accountability throughout the project lifecycle.
Automation as a Long-Term Capability
Perhaps the most important takeaway from the “Not Just Robots” discussion is this: automation is not a one-time purchase.
When designed correctly, a custom automation system becomes a platform—one that can evolve with new parts, higher volumes, and changing market demands.
By focusing on process understanding, system integration, and flexibility, manufacturers position themselves to adapt faster and compete more effectively.
Automation, in this context, isn’t about replacing people or installing machines. It’s about making manufacturing better—one well-engineered system at a time.
Continue Learning
To see these concepts in action, including examples, controller features, motion coordination, and project case studies, watch the webinar replay “Not Just Robots—Custom Automation Built Around Your Process.” You’ll hear directly from the ASG team, including their approach to SOW intake, concept simulation, safety validation, and real production deployments
To explore more educational resources, webinars, and automation insights, visit motoman.com.