The smart revolution: how robotics is reshaping manufacturing and end‑of‑life processes
Manufacturing is at a turning point. Across sectors, organisations are being asked to produce more sustainably, make better use of materials, and deal responsibly with what happens when products reach the end of their working life. At the same time, labour shortages, safety concerns and rising costs are putting pressure on traditional ways of working.
Against this backdrop, robotics, artificial intelligence and autonomous systems are starting to move from the edges of manufacturing into the mainstream. Not as a silver bullet, but as practical tools that can help industry rethink how products are built, used, repaired and recovered.
A recent IET Manufacturing Technical Network webinar explored what this “smart revolution” looks like in practice. The discussion covered everything from circular manufacturing and value retention to remote robotics in hazardous environments. What emerged was a clear message: the future of manufacturing will be collaborative, cross‑sector and very human‑centred. With two eminent academic speakers, we covered the following topics.
- Prof Samia Nefti-Meziani OBE Professor of Robotics and Artificial Intelligence at the University of Birmingham
Towards Circular Manufacturing and Materials: Opportunities and Challenges of RAS Adoption Across Industrial Sectors. This presentation examines value retention processes and highlights the challenges and opportunities associated with adopting Robotics, Artificial Intelligence, and Autonomous Systems (RAS). It further discusses how cross-sector collaboration can drive and accelerate the deployment of RAS in circular manufacturing and materials sectors.
- Prof Guido Herrmann Professor of Robotics and Intelligent Control & Head of Control Systems and Robotics Group, University of Manchester
Bridging the gap between novel control and robotics research and real-world applications within the UKRI-funded AMPI project, Prof Herrmann discusses human–robot interaction, digital twins, and control strategies for effective collaborative tele-robotic systems with compliant soft robot hands in glovebox, biosafety cabinets, also within extreme environments.
The growing challenge of end‑of‑life manufacturing
One of the biggest pressures facing manufacturers today is what happens at the end of a product’s life. High‑value products such as wind turbines, electric vehicle batteries and complex medical devices are reaching decommissioning at scale. In the UK and Europe alone, the volumes involved are rising quickly, and current systems are struggling to cope.
At present, much of this material is exported for processing, only for recovered materials to be bought back later. This approach is costly, inefficient and raises serious sustainability concerns. It also creates dependency on external supply chains for critical materials that are essential to the net zero transition.
The problem isn’t a lack of intent. It’s a lack of suitable processes and technologies that can deal with complex products safely, efficiently and at scale. Many existing end‑of‑life processes rely on manual work, low levels of automation and limited innovation. That makes them hard to scale and difficult to improve.
From recycling to value retention
A key shift highlighted in the discussion was the move away from seeing recycling as the only option. Instead, there is growing interest in a wider set of “value retention processes” such as reuse, repair, refurbishment, remanufacture and repurposing.
These approaches aim to keep products or components at their highest possible value for as long as possible. In many cases, this is far more resource‑efficient than breaking products down into raw materials. However, these processes are also more complex. Products are often not designed to be taken apart, components vary widely in condition, and safety risks can be significant.
This is where robotics and AI begin to make a real difference. Intelligent systems can help with inspection, disassembly, handling and sorting, even when products are damaged, corroded or inconsistent. Importantly, these systems don’t need to replace people. Instead, they can support skilled workers, reduce physical strain and make difficult tasks safer.
Why collaboration matters
One strong theme running through the webinar was the importance of cross‑sector collaboration. No single industry has all the answers, but many face similar challenges. Techniques developed in one sector can often be adapted for another.
For example, robotic systems originally designed for handling flexible food products can be repurposed for dealing with contaminated waste materials. Soft robotics developed for safe human‑robot interaction can be applied to repair and refurbishment tasks where delicate handling is essential. Lessons learned in nuclear decommissioning can inform approaches in energy, aerospace or medical manufacturing.
This kind of collaboration also helps to reduce risk and cost, particularly for small and medium‑sized enterprises. When technologies can be applied across multiple sectors, they become easier to justify, easier to scale and more attractive to invest in.
Robots, people and trust
Another important point was that automation doesn’t have to mean removing people from the process. In many cases, especially where tasks are complex or safety‑critical, human judgement remains essential.
Remote and semi‑autonomous robotic systems offer a useful middle ground. By allowing operators to work at a distance, they can reduce exposure to hazardous environments while still benefiting from human decision‑making. Shared control systems, where robots assist rather than override operators, can improve precision and reduce fatigue without taking control away from the person.
Building trust in these systems is crucial. That means clear regulatory pathways, agreed standards and opportunities to test new approaches in realistic settings. Regulatory “sandboxes” and testbeds were highlighted as valuable ways to explore how new technologies can be deployed safely and responsibly.
Designing for the future
A recurring challenge is that many products are not designed with end‑of‑life in mind. Components are glued, sealed or welded in ways that make automated disassembly extremely difficult. As a result, even the most advanced robotic systems are forced to work around design decisions made years earlier.
There is a growing recognition that designers need better tools and guidance to think about circularity from the outset. Digital twins, inspection data and feedback from end‑of‑life processes can all play a role in informing better design decisions upstream.
Over time, this could help create a virtuous circle where products are easier to repair, reuse and recover, and where automation can be deployed more effectively.
Skills for the next generation
The discussion also touched on what all this means for engineers and technologists coming into the profession. While AI and software tools are becoming more accessible, strong foundations still matter. Mathematics, systems thinking and a solid understanding of how technologies work under the surface remain essential.
Robotics was highlighted as a particularly valuable entry point because it brings together mechanics, electronics, control, software and human factors. It also encourages teamwork and problem‑solving, skills that are increasingly important in complex manufacturing environments.
Early engagement is key. Introducing young people to engineering concepts at primary and secondary school level can shape confidence and career choices long before formal specialisation begins.
Taking the first step
For organisations wondering where to start, the message was reassuringly simple. Focus on the problem, not the technology. Look for areas where automation or robotics could make work safer, more consistent or more sustainable. Start small, learn from other sectors and build from there.
The smart revolution in manufacturing is not about chasing the latest trend. It’s about using the right tools, in the right way, to build a more resilient and sustainable future.
IET Manufacturing Technical Network
This webinar is part of the annual event series organised by the volunteers of the IET Manufacturing Technical Network. We welcome your suggestions for future topics and expressions of interest to present at our webinars. Follow us on LinkedIn at linkedin.com/company/iet-manufacturing-technical-network and get in touch by emailing manufacturing-TPN@ietvolunteer.org
Question
As more robotics and AI are introduced into manufacturing, where do you see the biggest opportunity for human skills to add value rather than be replaced — design, operation, decision‑making, or something else?