Between 2003 and 2006, the rate of increase in the use of industrial robots in South Africa was higher than that of Germany, albeit from a low base, and the increase is expected to continue, with more small companies creating robotic automation applications, as well as an increase in robotics and automation in larger companies.

The use of robotics reduces the cost per part and increases the volume capacities of companies. The automotive industry, including the assemblers and their suppliers, is the biggest user of robotics, says Weinert.

He notes that, although it has a long way to go to equal the automation levels of the European and Asian industries, the local industry’s rate of robotic automation is surely increasing.

Further, he observes that smaller manufacturers of high-volume products with highly repetitive and relatively laborious production and materials handling processes, such as the metal casting or cement repackaging industries, are trending towards robotic and conveying automation.

However, the rapid increase in robotic automation in industry is faster than the supply of skills from education and training.

“Few universities, and even fewer technical colleges, have cutting-edge, industrially- relevant training equipment in their practical labs, or competent staff able to teach the rapidly evolving technology. A bottleneck of increased use of robotic automation is also shown by the relatively few mechatronic engineers being produced, for whom robotics is a central part of their curriculum,” Weinert says.

The Manufacturing, Engineering and Related Sector Education and Training Authority (Merseta) lists mechatronic engineering as one of the scarce skills in the industries in its sector.

Weinert says the robotic expertise of the country appears to be concentrated in relatively few small robotic system integrators, with larger companies finding it fairly difficult to develop, employ and retain the necessary skills.

Robotics Training

Festo Didactic offers various levels of robotic training and its technical foundation courses provide the basis for robotic technology, such as pneumatics, stepper and servodrives, mechatronic systems and programmable logic controllers that include the new language standards, such as the controller development system.

“Festo’s robotic training is hands-on, [and involves] learning by doing three-dimensional virtual reality simulation. Once participants are conversant with the programming, they can start exercises on physical six-axis robots and ancillary parts, handling equipment such as grippers, magazines, assembly jigs, sensors and logic controllers,” Weinert says.

The training is generic and not product specific, as Festo Didactic targets “training for productivity” by teaching the technological principles that make a high impact on a customer’s productivity in the workshop, he adds.

Festo’s standard course is done over three days but the company also offers a consulting service, which includes a training needs analysis as well as the customisation of course content to match the training needs. The course can also be extended to five days to include advanced handling and interfacing with other technologies.

Festo Didactic is Merseta-approved and participants receive a Festo certificate following their completion of the course.

“However, the most effective reference is the feedback from customers where Festo’s hands-on courses have made a real impact on improving productivity and increasing quality [and] decreasing downtime as well as maintenance costs,” Weinert concludes.