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In recent years, factory floors across Australia have seen a welcome rise in industrial and collaborative robots. Yet despite the investment, too many manufacturers find themselves in a familiar bind: the robot is physically installed, but it’s either underperforming, sitting idle, or worse – still operating with the same code from the day it was commissioned.
If that sounds familiar, you’re not alone. Globally, it’s estimated that up to 30% of industrial robots are underutilised due to outdated programming, misalignment with current production needs, or lack of integration into new processes.
At Industrial Robotics, our team has been called in to rescue countless systems — and we’ve learned that the root problem is rarely hardware. It’s programming, adaptability, and alignment with the business’s evolving production goals.
The New Reality: Robots Need to Be Flexible
Today’s manufacturing environments demand agility. Long gone are the days of year-long production runs with a single part number. Small and medium-sized manufacturers are increasingly moving toward high-mix, low-volume production — and robots must keep up.
This is where flexible programming strategies come into play.
Programming Options Beyond the Basics
Many robots installed in Australian factories are still running legacy code written for single-use tasks or inflexible production routines. That’s not a flaw in the robot — it’s a sign that your programming strategy needs an upgrade.
Here’s how we help manufacturers rethink robotic programming:
1. Block-Based Development Frameworks (BDF)
Ideal for manufacturers with limited in-house robotics expertise, BDFs provide a drag-and-drop or modular approach to programming. Operators can modify actions, triggers, and sequences without needing to write code from scratch.
⚙️ Best for: Rapid prototyping, small batch runs, and teams looking to reduce reliance on external integrators.
2. Offline Programming (OLP)
OLP allows us to program robots in a virtual environment while the robot is still operating on the floor — eliminating downtime.
We use tools that simulate real-world constraints (collision detection, reach analysis, cycle time estimates), so you can test and validate a new task before pushing it live.
⚙️ Best for: Frequent changeovers, custom part lines, and lines where every hour of uptime counts.
3. Classic Line-by-Line Programming
In cases where tight cycle times, advanced coordination, or complex IO are involved, we can develop custom scripts using standard robot languages (e.g. RAPID for ABB, KRL for KUKA, URScript for UR). We optimise for speed, precision, and repeatability — often improving legacy code efficiency by 10–30%.
⚙️ Best for: High-volume, precision-critical processes and legacy robot upgrades.
4. Hybrid & Adaptive Models
Not every project fits into a box. We often deploy hybrid solutions, combining BDF or HMI front ends with underlying script logic that allows skilled operators to adjust key parameters in real-time — without rewriting core code.
Need a Tailored Solution? That’s Our Strength.
Every robot has potential — but unlocking it requires more than just software. It requires a clear understanding of:
- Your production goals
- Your team’s technical comfort
- Your batch sizes and product diversity
- Your uptime requirements and constraints
At Industrial Robotics, we don’t just install and walk away. We offer consultation services to:
✅ Review existing equipment and programming
✅ Map production workflows
✅ Recommend suitable programming architecture
✅ Develop an automation roadmap for growth
✅ Train your team on how to manage future changes
Don’t Forget our RoboTradies
We also operate RoboTradies — our workforce support program, helping you upskill your team and build confidence in managing and modifying your robotics systems. Whether it’s integrating vision systems, adjusting path logic, or adding new grippers, RoboTradies supports your people as you evolve your processes.
Our goal? A sustainable automation solution that grows with your business.
Before You Buy New, Rethink What You’ve Got
If you’re considering another robotic investment, stop and ask:
Is the equipment I already own doing all it could be?
In many cases, with the right programming and system integration, your existing robots can be repurposed or upgraded to meet current needs — avoiding unnecessary capital expenditure.
Let us help you assess your options. Whether it’s a reprogramming job, a full redeployment, or a long-term automation strategy, Industrial Robotics is ready to step in and get your systems back on track.
Over the past year, we’ve had a steady stream of customers come through the doors at Industrial Robotics with one key issue: robots aren’t doing the job they were bought for. We offer industrial robot and cobot reprogramming and redeployment for Australian manufacturers
Some were never properly commissioned.
Others were programmed for a different task and never updated.
In some cases, they were installed by providers who are no longer in business.
Regardless of the cause, idle or underperforming robots represent a missed opportunity for Australia’s manufacturing future.
At Industrial Robotics, we are experienced in reprogramming, recalibration, redeployment – and ultimately getting robotic systems running the way they should. Whether it’s a packaging cell, welding station, or palletising setup, we have the team and tools to restore productivity and extend the value of existing automation investments.
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Why It Matters Now
As Australia accelerates its reshoring of manufacturing and invests in sovereign capability, factory automation is no longer optional – it’s essential.
📊 According to McKinsey, automation can reduce operating costs by up to 25% and improve throughput by 30% or more when properly implemented.
📉 Yet globally, it’s estimated that up to 30% of installed industrial robots are underutilised or misconfigured.
Closer to home, Australia’s industrial robot density still lags behind global leaders – but this is changing fast as local manufacturers retool for resilience and growth.
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Didn’t Buy from Us? No Problem.
At Industrial Robotics, we understand that not every robot on your floor came from us – and that’s okay.
Whether your system was delivered by another integrator, purchased second-hand, or has simply outgrown its original configuration, our engineers can step in to reprogram, retrofit, and redeploy existing hardware to suit your current needs.
Our team has experience across major industrial and collaborative platforms including:
- ABB
- Universal Robots
- KUKA
- FANUC
- OMRON
- Yaskawa
- Comau
- Delta
- SCARA
- SCADA
- PLC
- And more
We specialise in:
- Rewriting or optimising robot programs
- Updating tooling, grippers, and vision systems
- Integrating robots into new work cells or production lines
- Troubleshooting legacy issues and improving reliability
You don’t have to start from scratch — with the right programming and integration expertise, we can help you get more value from the equipment you already own. Learn more about IR maintenance.
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Our message to manufacturers: Before investing in new equipment, take stock of what you already have. There may be untapped capacity sitting idle on your factory floor.
If you’re sitting on a robot that’s not delivering ROI, we can help. Let’s get your automation working for you – not collecting dust.
📩 Get in touch with the Industrial Robotics team to assess your setup. Click Here!
Can’t find what you are looking for? No problem! Our staff are happy to quote you the right parts and service for the job. Investing in automation should be simple, scalable, and supported – from the first line of code to the last day of operation. Plus, if you need training or a HR consult, RoboTradies is here to help!
Phone 07 34173473
