KOBİ'lerde İşbirlikçi Robotların Entegrasyonu: Otomotiv Yan Sanayinde Bir Vaka Çalışması

Abstract

Amaç: Endüstri 4.0’dan Endüstri 5.0’a geçiş süreci, ileri otomasyon teknolojileri ile insan odaklı üretim sistemlerine olan ilgiyi artırmıştır. Bu bağlamda işbirlikçi robotlar (cobotlar), insan-robot iş birliği yoluyla hem operasyonel performansı hem de çalışan ergonomisini geliştirme potansiyeline sahip önemli bir teknoloji olarak öne çıkmaktadır. Ancak bu avantajlara rağmen, küçük ve orta ölçekli işletmelerde (KOBİ’ler) cobot benimsemesi; yüksek yatırım maliyetleri ve yatırımın geri dönüşüne ilişkin belirsizlikler nedeniyle sınırlı kalmaktadır. Bu çalışmanın amacı, KOBİ’lerin kısıtları ve karar verme ihtiyaçları dikkate alınarak geliştirilen, pratik ve insan odaklı bir cobot entegrasyon çerçevesini ortaya koymak ve ampirik olarak doğrulamaktır. Yöntem: Çalışmada; süreç yeniden tasarımı, performans değerlendirmesi ve ekonomik fizibilite analizini bir araya getiren sekiz aşamalı bir cobot entegrasyon çerçevesi önerilmektedir. Önerilen çerçeve, otomotiv yan sanayinde faaliyet gösteren ve jant üretimi yapan bir KOBİ’de gerçekleştirilen simülasyon tabanlı bir vaka çalışması ile test edilmiştir. CNC işleme hücresindeki yükleme ve boşaltma operasyonları Ayrık Olay Simülasyonu kullanılarak modellenmiştir. Mevcut manuel sistem ve cobot entegre edilmiş sistem olmak üzere iki senaryo analiz edilmiştir. Çevrim süresi, günlük üretim miktarı ve genel ekipman etkinliği (OEE) gibi temel performans göstergeleri değerlendirilmiş; ayrıca yatırımın ekonomik uygulanabilirliğini belirlemek amacıyla geri ödeme süresi analizi yapılmıştır. Bulgular: Simülasyon sonuçları, cobot entegrasyonunun mevcut sisteme kıyasla çevrim süresini yaklaşık %6 oranında azalttığını göstermektedir. Günlük üretim miktarı 240 parçadan 267 parçaya yükselirken, OEE değeri %70,8’den yaklaşık %82 seviyesine çıkmıştır. Ekonomik analizler, cobot yatırımının yaklaşık 1,55 yıl içerisinde geri kazanılabileceğini ortaya koymakta ve önerilen yaklaşımın KOBİ’ler açısından finansal olarak uygulanabilir olduğunu göstermektedir. Sonuç: Elde edilen bulgular, simülasyon tabanlı analiz ve süreç yeniden tasarımı ile desteklenen cobot entegrasyonunun KOBİ’ler için ölçülebilir operasyonel ve ekonomik faydalar sağlayabileceğini doğrulamaktadır. Önerilen çerçeve, Endüstri 5.0 ilkeleriyle uyumlu, yapılandırılmış, veri temelli ve sürdürülebilir bir karar verme süreci sunmaktadır. Özgünlük: Bu çalışma, KOBİ’lere özel olarak tasarlanmış bütüncül ve pratik bir cobot entegrasyon çerçevesi sunarak literatüre katkı sağlamaktadır. Önceki çalışmaların çoğunlukla teknik uygunluk veya güvenlik boyutuna odaklanmasının aksine, bu araştırma; insan odaklı tasarım, simülasyon tabanlı performans değerlendirmesi ve ekonomik analizleri tek bir karar destek yapısı içinde bütünleştirmektedir.

Keywords

• İşbirlikçi Robotlar
• Küçük ve Orta Ölçekli İşletmeler
• Ayrık Olay Simülasyonu
• Operasyonel Performans

Integration of Collaborative Robots in SMEs: A Case Study in the Automotive Sub-Industry

Abstract

Purpose: The transition from Industry 4.0 to Industry 5.0 has increased interest in human-centered production systems that focus on advanced automation technologies. In this context, collaborative robots (cobots) stand out as an important technology with the potential to improve both operational performance and worker ergonomics through human-robot collaboration. However, despite these advantages, cobot adoption in small and medium-sized enterprises (SMEs) remains limited due to high investment costs and uncertainties regarding return on investment. The aim of this study is to present and empirically validate a practical and human-centered cobot integration framework developed by considering the constraints and decision-making needs of SMEs. Methodology: The study proposes an eight-step cobot integration framework that combines process reengineering, performance evaluation, and economic feasibility analysis. The framework is tested through a simulation-based case study conducted in an SME operating in the automotive supply industry, specifically a wheel manufacturing facility. A CNC machining cell’s loading and unloading operations were modeled using Discreate Event Simulation. Two scenarios were analyzed: the existing manual system and a cobot-integrated system. Key performance indicators, including cycle time, daily production output, and overall equipment effectiveness (OEE), were evaluated. Additionally, a payback period analysis was conducted to assess economic viability. Findings: Results indicate that cobot integration leads to a cycle time reduction of approximately 6% compared to the existing system. Daily production output increased from 240 to 267 parts, while the OEE value improved significantly from 70.8% to nearly 82%. The economic analysis reveals that the cobot investment can be recovered within approximately 1.55 years, demonstrating the financial feasibility of the proposed approach for SMEs. Results: Cobot integration, when supported by simulation-based analysis and process reengineering, can deliver measurable operational and economic benefits for SMEs. The proposed framework enables firms to manage cobot investments through a structured, data-driven, and sustainable decision-making process aligned with Industry 5.0 principles. Originality/Value: This study contributes to the literature by offering a holistic and practical cobot integration framework specifically designed for SMEs. Unlike prior studies that focus primarily on technical feasibility or safety aspects, this research integrates human-centered design, simulation-based performance evaluation, and economic analysis within a unified decision-support structure.

Keywords

• Collaborative Robots (Cobots)
• Small and Medium-Sized Enterprises (SMEs)
• Discrete-Event Simulation
• Operational Performance

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