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Procedia Manufacturing 00 (2019) 000–000
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Procedia Manufacturing 51 (2020) 73–80

30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2020)

15-18 June 2020, Athens, Greece.
Development of a new robotic programming support system for operators
Colombet Emerica, Debled Geoffroya, Dossou Paul-Erica,b*
aIcam site of Paris-Sénart, 34 Point de vue,77127 Lieusaint, France

bUniversity
University Gustave Eiffel/AME/SPLOTT, 14-20, Boulevard Newton, 77420, Champs-Sur-Marne, France

* Corresponding author. Tel.: +33181141043; E-mail address: paul-eric.dossou@icam.fr

Abstract

Globalization introduces a high diversity of customer expectations and incertitude for the future of companies. Indeed, the level of labor cost in
Europe imposes to European companies to improve their performance in terms of cost, quality, lead time but also on social, societal and
environmental aspects, as much as innovation, and integration of new technologies (blockchain, Internet of things, cobots, robots etc.). Thus,
Industry 4.0 concepts could be implemented in companies by integrating technologies (machines, AGVs, robots, cobots) and using new tools
such as IoT, RFID and decision aided tool (based on Artificial Intelligence concepts). The definition of the industry of the future also needs to
integrate social, societal and environmental aspects for taking into account the particular context of the company being transformed. This paper
focuses on problems due to cobots implementation in a manufacturing system, such collaboration with people in the elaboration of a product.
Beyond, the problem of safety, that could be studied in detail, many other challenges have to be raised. For instance, the problems of flexibility
due to product diversity and versatility of customer demands or pieces recognition transfer in a pick and place electronics process, have to be
solved. This paper presents concepts, methods and structure for developing a decision aided tool (robotic programming support system) using
various technologies (tool, IoT, Vision) for increasing the cobot level of success in the pick and place operation. A detailed illustration example
will be presented to validate the elaborated concepts. Perspectives will explain this research next steps.

© 2020
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Keywords: programming support system , robotics , HMI , operator

1. Introduction implementations. A specific framework, taken into account

Industrial transformations started since 1765 from
industry1.0 as the mechanical production. Evolutions have
continued through industry 2.0 as mass production and
industry 3.0 as automated production. Nowadays, the
European industry is currently undergoing major changes in
the frame of industry 4.0. Indeed, connected objects (IoTs),
data, cobots, robots, software, artificial intelligence and other
technologies are key drivers of theses changes. Another
challenge for Industry 4. 0 is the implementation of its
concepts in SMEs. One objective is to define a framework in
order to find brakes of industry 4.0 implementation in SMEs
and to define levers to use for increasing the number of these
social, societal and environmental aspects, has been
developed for aiding during the implementation. This paper
presents one way of the framework exploitation for
implementing industry 4.0 concepts in electronics
manufacturing SMEs.
Indeed, the increasing labor cost in the developed countries
has during the last years motivated the investment in
industrial robot systems. This especially has an impact on the
robotization of small and medium sized enterprises
(SMErobot™). Differently from large enterprises which
normally have their own competent staff, SMEs require more
support and knowledge transfer to be able to efficiently utilize
the industrial robot technology (SMErobot™). The questions

2351-9789 © 2020 The Authors. Published by Elsevier Ltd.

2351-9789
This is an©open
2020 The Authors.
access Published
article under bytheElsevier Ltd.
CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open under
Peer-review access article under the CC
responsibility BY-NC-ND
of the license
scientific https://creativecommons.org/licenses/by-nc-nd/4.0/)
committee of the FAIM 2021.
Peer-review under responsibility of the scientific committee of the FAIM 2020.
10.1016/j.promfg.2020.10.012
74 Colombet Emeric et al. / Procedia Manufacturing 51 (2020) 73–80
2 Author name / Procedia Manufacturing 00 (2019) 000–000
are about the level of automatization, the place of operators,
and the collaboration between robot and people for increasing
the company performance.
Lean manufacturing is one way for company performance
improvement. In this case, Value stream mapping (VSM)
could be used for defining takt times for manufacturing
processes, reducing costs in addition to lead time and
increasing quality. In electronic manufacturing SMEs, small
and medium series, are frequent. The company must focus on
series changes (Single Minute Exchange of Die (SMED)) and
reduces their duration. Then, the company global organization
has to be improved and the problem of collaboration between
people and robot has to be solved.
This paper focuses of the last point. The programming of a
robot or cobot can be long, meticulous and often requires
significant robotics skills. To reduce changeover times, robot
programming must be fast, simple and efficient. In addition,
the company may own one or more brands of robots. But two
big pillars of Industry 4. 0 are flexibility and agility. In fact,
operators must be able to program all brands of the company
robots in order to guarantee this agility. The operators are then
at the heart of the process. They have to be autonomous in the
robots programming and in tasks associated to the production
system. The collaboration between robot and human becomes
indispensable.
However, there are as many programming languages as
there are robot brands. The objective of this research is to
develop a programming aided tool for simplifying robot
management by operators.
After a literature review, concepts and methodology for
industry 4.0 will be presented and a focus will be made on the
methodology for developing a new robotic programming
support system. The global architecture and structure of this
tool will be shown, and an illustration will be described.
2. Literature review
This paper aims to accelerate the use of industry 4.0
concepts in SMEs (specially electronics SMEs) by detecting
brakes of their implementation and levers for improving
performance of these companies. Social, societal and
environmental aspects are crucial for SMEs in any new
technologies deployment and are considered as the main
problem to solve. The collaboration between operators and
robots is important and has to be optimized. The development
of a new robotic programming support system for operators
will encourage this optimization. This chapter presents the
synthesis of the state of the art required for developing this
tool.
2.1. Industry 4.0 concepts
Many researchers have worked on framework for industry
4.0. Most of them are focused on new technologies. In [1]
industry 4.0 is organized around three dimensions:
• Horizontal integration (value creation network)
• End-to-end engineering (product life cycle)
• And vertical integration (networked manufacturing
systems)
This framework could be used for structuring the
organizational and technological dimensions. These aspects
could also be improved by frameworks presented:
• in [2] which focused on digitalization (new technologies):
cyber-physical systems, big data real time data
management, IoT, traceability, etc.
• in [3] developed around the idea of smart factory and smart
manufacturing.
• In [4] structured around economic aspects in processes.
The framework developed in [5] allows to combine
technological, and organizational dimensions with social,
societal and environmental aspects. Thus, the new
programming support system could be developed based on his
framework.
Standardize Define
Dashboard
GRAI METHODOLOGY & LEAN MANUFACTURING
Organizati
on
SME
Performance
improvement
Control
Sustainabi
lity
Measure
Flexibility
New
technologi
& changes es & tools
Dashboard
SME
Innovate Analyse
DMAIC & DESIGN OF EXPERIMENTS
Fig. 1. Description of the new framework for industry 4.0 implementation
Indeed, this framework serves for detecting brakes to
industry 4.0 and logistics 4.0 implementation in SMEs, but
also for determining levers able to accelerate the
implementation. The focus on sustainability which takes into
account social, societal and environmental aspects is an
advantage for the use of this framework in the development of
the new robotic programing support system for operators.
2.2. Robotic technical aspects
Robotic technical aspects are explained through the
following three sub-sections:
• Robotic tasks
• The various Man-Robot collaborations
• And safety in robotics
2.2.1. Robotic tasks:
Companies (SMEs, ETI, large groups) need to be
competitive and to improve their performance, then processes
automation and mechanization by using industrial robots
when it is possible are advisable. With Industry 4. 0, the use
of robot or cobot (collaborative robot) can respond to different
tasks and different ways of human-robot collaboration [6, 7,
8]. The questions are how a cobot could help an operator and
how to define tasks for robot or cobots and tasks for human.
Robots in many tasks could be more efficient than an
operator. Then it is important to dispatch tasks by integrating
all parameters such as ergonomics, efficiency, etc. The
robot/cobot as shown in Fig. 2, can easily perform tedious
 Colombet Emeric et al. / Procedia Manufacturing 51 (2020) 73–80
Author name / Procedia Manufacturing 00 (2019) 000–000
tasks such as pick & place, packaging or dangerous tasks
(chemicals, etc...) such as arc welding, painting.
Fig. 2. Pick and place operation by a cobot
This pick and place task could be combined with other
tasks realized by an operator such as fixing components, or
scotching boxes. All these applications have the virtue of
taking over the most difficult tasks and leaving the employees
to concentrate on other, more rewarding ones. There are many
advantages for companies to implement robots/cobots in their
processes. Indeed, economic factors such as reduction of labor
costs, flexibility of production management, decreasing of
stocks, quality improvement, detailed in [7] have to be
pointed out. But also, ergonomics, social aspects and
environmental conditions have to be associated to the
advantages. In Fig. 3, three modes of work are presented. The
best one is collaboration between cobot and human according
to a lean approach.
Fig. 3: Framework to implement collaborative robots in manual assembly: a
lean automation approach [9]
2.2.2. The various man-robot collaborations
Robotizing manufacturing lines can create apprehension of
operators. It is important to note the discrepancy between
these operator apprehensions when the robot arrives and his
75
3
satisfaction (pride) when he discovers the advantages of
collaborating with cobots and programming them [ 7, 10].
Collaboration between operators and robots is important
for increasing the company performance. Then it is necessary
to succeed in the company transformation management. There
are several human-robot collaborations as described in [8, 11,
12, 13] but the main company success story is based on
human as the kernel of changes.
There are at least 5 predefined cases as presented in Fig. 4 in
the different possible collaborations:
• Case 1: Working on the same piece, simultaneous actions
(direct collaboration)
• Case 2: Working on the same piece, alternating actions
(indirect collaboration)
• Case 3: Autonomous work on different parts (man/robot
coexistence)
• Case 4: Physical / gesture / handling assistance, robotic
systems of physical assistance guided by the operator
• Case 5: Physical assistance / gesture / handling, physical
assistance systems attached to the operator
Case 1 Case 2
Case 3 Case 4 Case 5
Fig. 4. Prevention Guide for Manufacturers and Users for the implementation
of collaborative robotic applications
In the development of these various cobotic applications,
operators are increasingly working alongside or even with
robots [6, 8, 14]. Thus, it is relevant for this change to give
operators autonomy and responsibility within cobot
applications.
2.2.3. Safety in Robotics
In cobotics, operator safety is paramount. Indeed, the various
man-robot collaborations have been studied in order to write
the different safety standards ISO-10218: 1 / 2 and TS:15066
[11, 12, 13]. These standards must be complied with for the
development of a cobotic cell within a company.
2.2.4. The different robotic brands and languages
In addition, there are many robot brands (Fanuc, ABB,
KUKA, Staubli, Omron, etc.) and each robot brand has its
76 Colombet Emeric et al. / Procedia Manufacturing 51 (2020) 73–80
4 Author name / Procedia Manufacturing 00 (2019) 000–000

own specific language [15, 16]. In the 80s, robot by the operators for reprograming robots will be an advantage
programming was simple and very basic. Today, robot for companies. The development of this tool implies the use
programming often requires training because of their of image recognition and artificial intelligence.
complexity and the use of new technologies. A new tendency
consists in the use of robotics open software tools such as
ROS, Matlab (for instance on Franka Emica robot) for sharing
knowledge with the robotics community. Indeed, Human-
Machine Interfaces (HMIs), based on simple robot tasks
programing, easy to be used by operators, have to be
developed, such as trajectories (for example the Kaktus
software from MC Robotics). This paper proposes to
elaborate a new robotics programing support system for
operators by integrating all collaborative modes described in
Fig.5.

Fig. 6. Specific tasks for cobots

2.4. Artificial intelligence

Many artificial intelligence formalisms are being exploited

Fig. 5. The four forms of collaboration identified by the robot safety
standards ISO 10218-1/2 [9, 10] and by the technical specification ISO/TS
15066 [11]
2.3. Flexibility within the industry
With Industry 4. 0, the goal is to make production lines
more agile, reduce costs, reduce changeover times and
increase throughput while customizing products. Lean
manufacturing methodology could be used for improving
SME performance. This methodology created in the frame of
Toyota Production System (TPS) allows to minimize non-
added values in manufacturing processes and to improve the
“value” by willing what the customer would pay for. Indeed,
the objective of lean manufacturing methodology is flow
optimization in processes, and the efficiency of any individual
resource of the system [17]. In this frame, the collaboration
between cobot and human could be increased and be used for
improving the company performance. By integrating a cobot,
the manufacturing area could be reduced in maintaining the
same production rates. In SME-ETI, the series can be small or
medium size. Robotizing these series is a high stake. Thus, an
intelligent robotization and automation of manufacturing lines
is required. Indeed, to optimize series changes, a fast machine
and robot reprogramming is required for making specific
tasks as shown in Fig.6. The idea is to make the operator
autonomous during these change phases. The creation of a
specific programming tool as an interface between
programming needed for robot and easy operations expected
in the literature for developing these typical software tools,
such as swarm intelligence [18], neural network [19], deep
learning [20] etc. Two of these concepts are adapted for
developing the new robotic programing support system tool:
• Expert system [21].
• And machine learning combined with multi-agent systems
(learning agent) [22].
Indeed, the following figure (see Fig. 7) describes how to
use expert system for linking human machine interface
(HMI), as desired in the programing tool, with the cobot and
mainly with input/output data associated to the manufacturing
process.
Human machine Interface
Inference Engine
Interpretation
module
Knowledge base Dynamic data base
Knowledge Base Management System
Fig. 7. Expert system architecture
This architecture is based on a knowledge management
system and data could circulate between this system and the
operator. These data would be transformed into adapted
information for the operators. The expectations of the
operators could also be transmitted into the knowledge base.
Machine learning is used in two phases:
 Colombet Emeric et al. / Procedia Manufacturing 51 (2020) 73–80 77
Author name / Procedia Manufacturing 00 (2019) 000–000 5

• The first is the step of observation for aiding the system to Learning Analyze a SME Expert
Find Brakes
learn by estimating the model and integrating data (input), machine existing system system

• The second is the step of the model exploitation the model

by adding new data for determining the right results. Analyse Brakes Expert
system
Design a SME
future system
Capitalization
system

This concept is interesting for recognizing forms and its Define levers of Expert
Define the
implementation
Transformation
acceleration system reasoning
combination with multi-agent systems (learning agent) [23] is steps

able to aid the operator for executing the right task. Define action
Capitalization Implement the Re-composition
plan for
system future system reasoning
implementation
The following section, based on the previous literature
review, presents the methodology elaborated for the Model a SME Decomposition
development of the new robotic programing support system existing system reasoning

and the analysis of scenarios that could be developed in this

frame. The global architecture of the tool corresponds to a
hybrid intelligent system (expert system, neuronal approach,
machine learning, and multi-agent system). Indeed,
reasonings such as case-based reasoning, transformation,
decomposition reasoning, are exploited in the elaboration of
the software tool. The IHM is defined for exploiting IoT
concepts and new technologies (virtual reality for giving
operators an image of changes, full-web applications). This
structure is also presented at the end of the next section.
3. Concepts and methodology
3.1. General approach
The use of new technologies in the frame of industry 4.0 is
crucial, but for SMEs, operators are the kernel of their
success. Industry 4.0 concepts implementations in these
companies will contribute to change their organization, by
eliminating all non-added values and optimizing all processes.
For a company, the objectives are to determine as presented in
Fig. 8, brakes to industry 4.0 implementation, to find levers
for accelerating this implementation and to continuously
improve the company performance by putting human as the
kernel of the company changes. The formalisms adapted to
each step of the process is also presented in the figure. Four
axes are defined for making the company transformation
(with human as the kernel) in the frame of industry 4.0 a
success [22]:
• The use of new technologies and tools for optimizing
processes (for instance, cobots and mobile robots
collaborating with people)
• The company reorganization by using lean manufacturing
and DMAIC (Define, Measure, Analyze, Improve, Control
and Standardize) concepts
• The flexibility and changes management in real time by
exploiting market requirements and expectations,
• And sustainability (social, societal and environmental
aspects) concepts deployment as the kernel of the industry
4.0 implementation.
Fig.8. Process of industry 4.0 implementation in SMEs
The new tool being developed, combines the technical
aspects related to the use of a cobot in a process for increasing
performance and the sustainability aspect with human at the
center of the transformation as described in Fig. 9. A cobot
will not take the place of the operator but give him an
opportunity to increase his performance. For instance,
complex and repetitive tasks could be done by an operator in
collaboration with a cobot. One brake is associated to the
operator knowledge on cobot programming. Cobot
programming is important for optimizing processes but
requires from the operator, a perfect knowledge on the cobot
specific language. This language changes when the company
invests in another cobot. Then, the operator will have to learn
another language. The general knowledge of operators in a
company is not adapted to all these changes. The development
of the new robotic support system will allow to define for an
operator in a company a human machine interface containing
data, instructions and processes independent of the cobot
language and easy to learn and apply.
Fig.9. Process management with a human cobot approach
3.2. The architecture of the system
The framework presented above, is supported by a decision
aided tool for structuring data collected in SMEs and
transforming them in order to improve the company in the
frame of industry 4.0. The architecture presented in Fig.10
represents the structure of the decision aided system being
developed for supporting the industry 4.0 concepts
implementation in SMEs. A focus is made in this case on the
collaborating support system for facilitating the operator
78 Colombet Emeric et al. / Procedia Manufacturing 51 (2020) 73–80
6 Author name / Procedia Manufacturing 00 (2019) 000–000

collaboration with cobots. This software being developed, is • Adding new models to the coin recognition and positioning
composed of: algorithm.
• A user interface for managing human interaction with the • Reorienting bulk parts whose orientation is known.
cobot (new technologies, virtual reality, data management).
The operator will be able to enter data or simple program 4.1. Data necessary for programming simple movements.
in the system for using the cobots
• A machine interface for transmitting orders to the cobots, The following diagram (Fig.11) explains the hierarchy of
receiving information from the cobots or changing their the main features, indicating the attributes for each elementary
behaviors with dynamic data feature. This shows the minimum amount of data that the
• An interpretation module for facilitating cobot or operator operator must enter to create a functional program.
adaptations from dynamic data
• A tool manager for managing relation between modules of
the software tool.
• A reference model system for managing generic data
described in the tool for solving problems
• An expert system containing a rule base, a fact base, an
expert knowledge module and an Inference engine. Data
acquired on an activity sector are transformed for being
used in order to analyze a company of the sector and
improving its performance.
• An expert knowledge module for continuously capitalizing
expert knowledge and defining performance indicators and
mode of their measurement.
• A scheduler for calculating the cobot potential response
according to the operator instructions and comparing it to
the robot reaction. The idea is to be able to measure the
robot real behaviour and adapt it to operator expectations.
• A learning system for capitalising observed between
human expectations and cobots behaviour or cobots
expectations and human reaction.

Fig.11. Description of Modules hierarchy and arguments used in each

primary function.

The legend of the arguments associated to the previous figure

is described in table 1.

Table 1: Types of arguments:

Name: Type Example

GripAction List Open, Close
Fig.10. Architecture of a decision aided tool for managing human-cobot
collaboration in the frame of industry 4.0 Speed Int 22 (mm/s)
Force Int 20 (N)
4. Illustration scenarios OpeningLength Float 22,5 (mm)
X,Y,Z Robtar [[23],[45][65]]
The cobot used in this illustration is YUMI ABB cobot. get
The concept of our interface is to make the most common Speed List V1000
functionalities of Pick & Place applications by exploiting MvtType List z0
vision parameter for increasing cobot precision. This requires WorkObject Matrix Myworkobject
an intuitive, ergonomic interface limited to the most GetPosition() Robtar [[Robot.x][Robot.y][
frequently used functionalities. The most recurring problems get Robot.z]]
with Pick & Place applications in the electronics industries ReachSearchingPo Robtar Myimageposition
have been identified: sition() get
PatternName String Pattern01
• Programming simple movements, without using PatternFace String Pattern01_FaceA
inputs/outputs data or programming but only vision OriginalPattern’sP Robtar PosPattern01
acquisition simple tasks. osition get
 Colombet Emeric et al. / Procedia Manufacturing 51 (2020) 73–80
Author name / Procedia Manufacturing 00 (2019) 000–000
4.2. Add new models to the coin recognition and positioning
algorithm.
The following mock-up (See Fig.12) shows the HMI visual
aspect and ergonomics of the LearnObject tab. The aim of this
tab is to add pattern to recognize.
Fig.12. Mock-up of the HMI’s Visual part (LearnObjects).
WARNING: Before programing, the camera coordinate
system needs to be determined directly on ROBOTSTUDIO.
4.3. Re-orienting bulk parts whose orientation is known:
One way for treating lost in the reorientation of the models
is to call each side with letters using the 3D cube. That is a
real aid, for reducing or eliminating potential errors. The
figure below (Fig.13) allows the faces to be named according
to four different orientations of the part. The pins are the main
landmark, because in the example, their final position is to be
in the electronic board.
Fig.13. Object recognition according to faces
The figure below (see Fig.14) shows the steps to be performed
depending on the orientation of the part in Fig.13.
79
7
Fig.14. Different steps in order to re-orient the piece in the great position.
(For a simple Object).
4.4. Software and hardware
In the electronics sector, SMEs have invested in different
materials and tools. Various cobots are used as presented in
table 2. They don’t have the same characteristics but have to
be used sometimes for realizing the same tasks in companies.
Table 2: cobot characteristics comparison
In this example, the cobot has the following specificities:
• Hardware
○ Cobot YUMI dual-arm ABB
○ Camera Cognex in-Sight
The programming support system being developed has to
be able to use tablet or computer for exchanging with
operators.
Two options could be chosen.
• The first is to develop the tool completely independently to
the specific cobot language
• And the second is to use in-house with SDKs provided by
the different robot suppliers for realizing this development.
The second choice is validated because of the opportunity
to collaborate with suppliers and to exploit directly their
specificity.
The adapted and independent tool is being developed in a
second way in order to be able to change cobot work without
changing programing support system. The development and
the test of the tool will be presented as soon as possible.
80 Colombet Emeric et al. / Procedia Manufacturing 51 (2020) 73–80
8 Author name / Procedia Manufacturing 00 (2019) 000–000
The software tools exploited in this example are:
• Robotstudio
• Robotstudio PC SDK
• Visual Studio
• Cognex In-Sight SDK
This first development is possible because of the
collaboration with ABB company on their tools. The complete
test for checking independence of the tool will also need
collaboration with other cobot companies such as Fanuc,
Omron. An investment in the cobots CRX 10iA (Fanuc) and
TM5-900 (Omron) and IRB 1200-7 (ABB) is being realized
for managing the independent aspects.
Specifications for the development of the new supporting
tool are already defined and the elaboration of the software
tool has started. The validation and the test of the tool will be
done as soon as possible at the end of this phase.
4. Conclusion
This paper presents a project being developed on industry
4.0. Indeed, SMEs are very unwilling to change employers
and replace them by robot and new technologies. In this
paper, the framework developed for industry 4.0, presents the
advantage to put human as the kernel of all changes in
companies. Then, industry 4.0 concepts, integrating new
technologies, in addition to new organizations and combining
them with lean manufacturing could be implemented for
increasing SME performance. The paper argues on the
necessity to develop a new programming aided tool for
combining with success cobot and operator tasks on a
manufacturing process.
In this paper a zoom is made on developing the vision for
the pick & place tasks and the adapted program. This function
will allow operators to include new parts to be handled and to
configure the picking and dropping of these parts. These parts
are of complex shapes such as electronic components to be
placed on boards. The desired accuracy is in the micron range.
The global specifications of the open software tool are
already done. The Intelligent HMI is being elaborated and
will be validated, tested and presented as soon as possible.
The next step for this development will be on the combination
of different tasks for the cobot such as packaging after a pick
and place. The optimization of the SME processes by
exploiting lean manufacturing will be shown through the
exploitation of SMED tool for managing the quick transfer of
the cobot from one production line to another in a very short
time (less than 6mn). The operator will manage all tasks
realization such as cobot calibration, pick and place process,
with his HMI without programming. The exploitation of
virtual reality in the HMI for facilitating the work of the
operator has to be integrated.
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