Robotics Division Overview Presentation

Improving…. ABB Robotics
Productivity Division Overview
Process Quality
Workplace Safety
© ABB

Facts about ABB

A leading power and automation
Headquarters: Zurich, Switzerland technology company with strong
More than 110,000 employees in market positions in core businesses
about 100 countries
We help our customers:
Orders in 2007: $34.3 billion
to increase industrial productivity
Revenues in 2007: $29.2 billion
to use electrical power efficiently
Listed on Stockholm, Swiss & New
to lower environmental impact in a
York exchanges; traded on virt-x
sustainable way
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What we offer: divisional structure and portfolio
2007 revenues (US$) and employees per division

Power Power Automation Process
Robotics
Products Systems Products Automation
$9.8 billion $5.8 billion $8.6 billion $6.4 billion $1.4 billion
32,000 employees 14,000 employees 33,000 employees 26,000 employees 5,000 employees
Transformers, high- Substations, FACTS, Low-voltage products, Control systems and Robots, peripheral
and medium-voltage HVDC, HVDC Light, drives, motors, power application-specific devices and modular
switchgear, breakers, power plant & network electronics, and automation solutions manufacturing
automation relays automation instrumentation for process industries solutions for industry

Market-leading positions in most key product areas
Integrated solutions for grid reliability, productivity and energy efficiency
© ABB Robotics - 3

Robust global value chain to serve established and emerging markets
Extensive global network of value-added channel partners

Overview Agenda

Robotics Division
Markets Served
Products & Systems offer
Service offer
Summary
© ABB Robotics - 4

Robotics division
Markets served
Automotive and their Tier 1 suppliers
General industries including foundry, metal
fabrication, plastics, consumer electronics, food &
beverage, machine tools, solar, pharmaceuticals &
chemicals, wood

Key deliverables
Robots, application equipment and software
Standardized manufacturing cells for material
handling, machine tending, welding, cutting,
painting, finishing, etc.
Engineering for systems in press automation,
body-in-white, paint processes, power train
assembly
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Product & systems service

Robotics division - key facts

2007 Orders $1.6 billion
5000 employees in over 45 countries
Manufacturing in 3 regions, Europe,
Asia & America
Sales & Service operations in over 45
countries & over 100 locations
Introduced painting robots in 1969 and
the worlds first commercially available
electric robot in 1974
Over 160,000 robots installed
worldwide at end 2007
© ABB Robotics - 6

Two channel market approach

Customers & Users

Direct sales Indirect sales
Channel Partners
-System Integrators
-Machine builders (OEM’s)

Robots, Robot Cells, Systems, Service
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Global Partner Program in robotics
Global program for System Integrators
and Machine Builders
Robot integration on 3 levels, Partner,
Preferred Partner & Strategic Partner
Benefits of ABB’s Partner Program
Partner agreement
Invitation to Partner Seminars
Premium Partner Web
Image & Visibility
Partner symbols
Partner reference stories
Exhibitions & Seminars
Sales material
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Demo robots & cells
Sales support & training

Global Reach, Local operations
© ABB Robotics - 9

Present in 45 countries - in more than 100 locations

Experience from 160,000 + robot installations

Other processes
and assembly Arc welding

Painting

Material handling & Spot welding
Machine tending
© ABB Robotics - 10

Continuous technology development
Joystick motion control MultiRobot control
S2 Robot Controller TPU MultiMove
Hydraulic paint robot
Electric Paint Robot Modular Controller
Trallfa TR-200
TR5400 Touch screen HMI
IRC5 controller
6 axis electric robot
IRB90 High-speed Picker
IRB340 FlexPicker

Open Architecture
S4 Controller

1970 1980 1990 2000

AC Servo Drive system
IRB2000
Arc weld process
simulation
VirtualArc
First electric robot Modular Design
ASEA IRB6 IRB6000 range
500kg robot

IRB7600
Dynamic Motion Control
TrueMove, QuickMove

Offline Programming & Simulation
RobotStudio

Hydraulic paint robot 6 axis electric robot Joystick motion control
Trallfa TR-200 IRB90 S2 Robot Controller TPU

1970 1975 1980 1985 1990

First electric robot AC Servo Drive system Modular Design
ASEA IRB6 IRB2000 IRB6000 range

“Innovation & technology are part of our DNA”

Open Architecture High-speed Picker MultiRobot control ForceControl
S4 Controller IRB340 FlexPicker MultiMove FC Machining
Modular Controller FC Assembly

Touch screen HMI
IRC5 controller

Electric Paint Robot
TR5400
Process Arm for AW
IRB1600ID

1995 2000 2005 2006 2007 2008

Dynamic Motion Arc weld process 2nd Generation Next Generation
Control simulation Motion control Safety Systems
TrueMove, QuickMove VirtualArc TrueMove, QuickMove SafeMove

Offline Programming & 500kg robot Compact paint robot
Simulation IRB7600 IRB52 with integrated IPS
RobotStudio

The top 10 reasons for robot investment

Increase production output rates
Reduce operating costs
Improve process quality
Improve workplace health & safety
Increase product manufacturing flexibility
Reduce material waste and increase yield
Reduce labour turnover and difficulty of recruiting workers
Save space in high value manufacturing areas
Reduce capital costs (inventory, work in progress)
Improve quality of work for employees

Based on research carried out by the International Federation of Robotics (IFR)

Overview Agenda

Robotics Division
Markets Served
Service offer
Summary

Segments Served - Overview

Metal Food &
Automotive Plastics Foundry
Fabrication Beverage

Chemical & Consumer
Machine Tools Wood Solar
Pharmacy Electronics

Automotive Industries Overview
Markets & applications served
Automotive components
Powertrain assembly
Press automation
Paint process automation
Body-in-white

Customer needs
Cost competitiveness
Higher production outputs
Zero defects
Capacity to meet continued growth in demand

ABB Offerings
Industrial robots with integrated application software
Fully engineered systems & cells
Vision guidance systems
Service agreements & productivity improvement
Simulation & offline programming software

Easy to use operator interfaces

Plastics Industries Overview
Automotive, electronics, medical, household goods,
Machine tending in injection moulding, blow moulding,
thermo forming
Water-jet, laser, ultrasonic and mechanical cutting
Dispensing, gluing and foaming, painting
Assembly, flame treatment and painting

Customer needs
Increased quality & reduced cycle times
Flexibility to accommodate short run production
Added production value to secure producers margins
Reduction in direct & indirect labor cost
Improved Health & safety

ABB Offerings
Robots, cells & systems via ABB & selected partners
Simulation & offline programming


Foundry Industries Overview
Sand casting, Gravity casting, Precision casting
Die casting
Forging & Lost foam
Handling, Machine Tending, Casting cleaning
Quality control, Surface treatment

Customer needs
Precision and improved process control
Improved Health & Safety
Reduce of waste and increased yield
Improve uptime, energy efficiency and productivity

ABB Offerings
Industrial robots for handling & finishing
Cells & systems via ABB & selected partners
Global solutions for vision & machining


Metal Fabrication Industries Overview
Agricultural, furniture, vehicles, white goods,
2-wheelers, construction equipment, trains, ships
Cutting, Welding and Joining
Forming, Inspection and Measuring
Material handling
Surface treatment, Finishing, Painting

Customer needs
Globalization and consolidation within the industry
High quality, capacity & efficiency
Automation due to shortage of skilled manual workers
Improved Health and safety

ABB Offerings
Industrial robots & application equipment
Systems & cells via ABB and selected partners
Standardized arc welding cells (FlexArc)


Food & Beverage Industries Overview
Food, beverage, pet-food, tobacco
Packaging, confectionary
Picking, Packing, Palletizing

Customer needs
Speed of delivery
Prolonged shelf life of products
Shorter product lifecycles, new packaging designs
and product variants
Increased uptime, yield & zero breakages
Improved Safety and Hygiene

ABB Offerings
Robots for picking, packing, palletizing
Systems, cells & solutions via selected partners

Vision & cell integration software

Chemical & Pharmaceutical Industries Overview
Pharmaceutical Drug Discovery & Production
Chemicals, Medical Devices
Personal & Home Care
Picking, Packing, Palletizing

Customer needs
Flexibility to handle different pack & product variants
Quality validation & traceability
Suitability for sterile production environments
Increased yyield

ABB Offerings
Robots for picking, packing, palletizing
Systems, cells & solutions via selected partners

Vision & cell integration software

Machine Tool Industries Overview
Precision machining including turning, milling,
grinding, drilling, …
Machine tending and handling
Quality control, Inspection
Surface treatment & part finishing

Customer needs
Automation due to shortage of skilled workers &
rising cost of labor
Flexibility to accommodate short run production
Consistent high part quality
Improvements in uptime and productivity
Improved Health & safety

ABB Offerings
Industrial robots for machine tending and post
processing (multiple tasks)
Dedicated machine interfaces

Service agreements & productivity improvements

Wood Industries Overview
Wooden furniture, flat-pack, doors, windows,
wood for building construction, kitchens
Handling, machine tending, painting, packaging,
finishing, palletizing, sanding, carving

Customer needs
Automation due to shortage of skilled workers /
rising cost of labor
Consistent high part quality
Improvements in uptime and productivity
Health & safety improvements
Better utilization of high cost machinery

ABB Offerings
Industrial robots & selected application
equipment
Vision guidance systems


Consumer Electronics Industries Overview
Markets and application served
Computers, mobile phones, digital cameras,
media players, games consoles, cameras
Laser welding, painting, grinding & polishing
Extraction, spraying and tending for die-casting and
injection molding machine cell
Palletizing/de-palletizing, assembly, picking &
packing

Customer Needs
Quality, precision and cosmetic finish
Short cycle time and high volume production
Short product life cycle production runs
Rising cost of labor and demanding H&S
Simple compact & flexible solutions

ABB Offering
Industrial robots and application equipment
Paint application systems

Grinding & polishing systems (Flex-finishing)
Simulation and off-line programming software

Solar Photovoltaic Industries Overview
Solar Photovoltaic power generation
Solar cell and module production (silicon and tf)
Material handling (ingots, wafer/cells, modules)
Module assembly, e.g. soldering, edge trimming

Customer needs
Increasing production capacity and efficiency
Reduction of production cost
Constant high product quality output
Standardization of production plans worldwide
with high-end, flexible automation/robotics

ABB offerings
Industrial robots for all applications including
Clean Room Class 5
Standardized ABB function packages for cell-
and module manufacturing


Other Industries Served

Building Materials

Defense & Aerospace

Glass products

Sanitary/Tableware/Ceramics

Overview Agenda

Robotics Division
Markets Served
Service offer
Summary

Robots & Systems overview

Application Manufacturing Automotive
Robots Software
Equipment Cells Systems

Comprehensive range Fully integrated Controller & PC Modular Fully engineered
of small, large, paint & process equipment based software to manufacturing cells automotive systems
dedicated robots with for arc welding, support robots & based on globally for BIW, Paint,
handling capacity handling, spotwelding systems throughout proven solutions. Powertrain & Press
from 1kg to 650 kg and painting their entire life-cycle. Tailored to local needs automation

Market-leading positions in key areas
Integrated solutions for productivity, process control & workplace safety

Global coverage serving established and emerging markets
Extensive global network of channel partners

ABB market offer: Robots

Robots and robot controllers Application equipment

Software

Industrial Robots - Overview

Picking
Packing
Palletizing

6 axis Robots Paint Robots Dedicated 4 axis Robots

Comprehensive range from 1kg to 650kg payload capacity
Robust, Rigid, Reliable, Easy to Use

Customization through modular design concept
Protection with Clean Room, Foundry Plus & Foundry
Prime (IP67), Wash Down

Small Robot family: Pay load 5 kg to 60 kg
IRB140 IRB1410 IRB1600

6kg 0.81m 5kg 1.44m 6-8.5kg 1.2/1.45m

IRB4400 IRB2400 IRB1600ID

Integrated Dressing

10-60 kg 1.95/2.55m 5-20kg 1.5/1.8m 4kg 1.5 m

Large Robot Family: Pay load 90 kg to 650* kg
IRB6620 IRB6660 Pre Machining IRB6660 Press Tending

150kg 2.2m 205kg 1.9 m 130kg 3.1m

IRB6650S IRB6640 IRB7600

* 650kg capacity
with wrist down

90-200 kg 3.0/3.9m 130-235kg 2.55/3.2m 150-500kg 2.55/3.5m

Painting Robots: with dedicated controller
IRB52 IRB540 IRB580/58

Compact Paint Specialist Flexiwrist & CP program Hollow wrist

IRB5400 IRB5500 IRC5Paint

Process or Slim Arm Car Body Painter Dedicated Paint Control

4 axis Robots: Picking, Packing, Palletizing
IRB360 FlexPicker IRB260 IRB660

High Speed Picker Top loader/Packer Palletizer
1-3kg 1.13m 30kg 1.5m 180-250kg 3.15m

Serving fully integrated
packing lines

Robot controllers

Modular Panel mounted Dedicated paint Graphical user
versions version version interface

Multi-robot control, up to 36 axis, with MultiMove
Programmable user interface with joystick motion control with FlexPendant

World leading motion control with TrueMove & QuickMove
“Next generation safety” with SafeMove
Powerful connectivity through network interfaces

Application equipment

Paint Process Equipment including
Atomizers
Integrated Process Dress Packs
Workpiece positioners
Process cabinets
Arc & Spot Welding process
equipment
Additional axis including tracks and
motor/gearbox units

Software – Delivering Power & Value
Nothing boosts productivity and
decreases the total cost of owning and
operating a robot based solution more than
a ABB Software Package.
ABB has developed a family of world class
software products to support every stage
of the robot life cycle.

Benefits include:
Reduced risk of operator mistakes
Less need for training
Application customization
Introduction of programmes & testing offline
Verifying new products quickly
Remote monitoring of production
Remote diagnosis of problems

Easy to use programmer interfaces

RobotWare for ”easy to use” interfaces

Spot welding & Arc welding
Plastics & DieCasting
Machining FC & Machine Tending
Assembly & Packaging
Press tending

RobotStudio for simulation & offline programming

Create a common view in the
planning stage
Verify tooling and fixtures in
the design stage
Program robots faster in the
start-up stage
Modify programs without
downtime in the production
stage

“RobotStudio is the
easy-to-use, low cost
software for visualization
and offline programming of

ABB robots. It is the tool
you need to maximize your
productivity”

Case Study - From six months to six days…
The Business Need:
A contract manufacturer uses plasma
spraying system to make parts
surface heat-resistant
Online programming had been
unsuccessful after more than 6
months
The customer did not approve
the part quality

The Solution & Benefits:
Higher part quality
With RobotStudio the CAD data was
utilized to quickly generate
a very accurate program
Cut programming time
A new program was created with
RobotStudio in half a day

Reachability
RobotStudio showed that the robot
could be placed in a better position in
relation to the part

Robot-based manufacturing cells - Overview

Spot Welding Arc Welding Painting/Coating Cutting

Press Tending Finishing Material Handling Machine Tending

Global robot-based solutions

2D & 3D Robot Vision
Guidance TrueView

Standardised ArcWelding
Cells FlexArc

Machining Function Packages
Machining FC FunPac

Standardized Finishing Cells
FlexFinishing

TrueViewTM vision guidance for robots
TrueView is a single camera, 3D
vision guidance system that allows
ABB robots to precisely locate
randomly presented & irregular parts
TrueView is tightly integrated to
the ABB robot
seamless integration
common components and
integration methodology
standard robot programming
modules
complete documentation for
installation and services
Recognized as best in class for
single camera 3D
Specified at Ford & Toyota

Growing success with Honda (1st
installations in US and Japan)
Over 200 Systems installed
globally

FlexArcTM – arc welding cells
Graphical interactive HMI on FlexPendant
Integrated weld error recovery
Integrated production monitoring
Intuitive production manager
Navigator software
Cell calibration
Tooling calibration
Part measurements
Cell check
Identical replicas of all cells available free in digital versions

Machining FCTM & FlexFinishingTM cells
Proven solution for robotic
grinding, deburring, polishing
and other mechanical finishing
processes
Integrated package for setup,
programming and production

Easy to integrate & deploy

Easy to use - Plug & Produce

Lead by hand programming

Easy relocation of cell within
production plant

Automotive Systems via Global Lead Centers
Press Automation
Body in White Assembly
Paint Automation
Power Train Assembly

Press Automation
From stack to rack ... Complete press shop automation !

Loading and unloading
of stampings

Racking of stampings

Body-in-White

Plug & Produce solutions
- from component assembly to body complete ...

FlexLean Modular Solutions

Paint Process Automation
Flexibility, high quality, low waste - from barrel to surface.

Sealing & coating

Paint equipment

Painting line

Powertrain Assembly
From assembly of engines & transmissions to full test...
… consistent quality and just in time!

Automotive Systems customers

Automotive Automotive

OEMs Tier One

Example of scope of supply in Automotive
Trimming and Foam Deposition Water Jet Cutting

Over US$ 167 million investment
Parts: Car seats Parts: Dashboards
Solutions for applying foam
in ABB equipment, systems
To produce the Megane II car
seats, ABB has supplied
robotized arc welding cells
and trimming plastic parts have
been provided for dashboard
manufacture.
and services Parts: Headliners (J84 version, Turkey)
ABB solutions have been installed for different
to various plants. applications in the headliner manufacturing process
including water jet cutting, handling and gluing.

Arc Welding

Body-in-White Robotized Applications

Parts: Car body (J84 version)
ABB has supplied complete turnkey systems Parts: Headlamps
to produce different body parts such as cross- ABB has supplied two robotized cells
members, floors, roof cross-members and rear for headlamp manufacturing.
back panels….

Paint Process Automation Body-in-White

The Megane II from Renault
Parts: Bumpers Parts: Cross-car beams for dashboard
ABB has supplied additional equipment ABB has supplied arc welding and handling
to the bumper paint line. turnkey solutions for cross-car beam assembly,
which are installed in Spain and France.

Body-in-White Body-in-White Paint Process Automation Paint Process Automation

Parts: Dashboards
Parts: Car bodies Parts: Car bodies Parts: Car bodies A complete paint line for dashboards has been
ABB has installed turnkey robotized solutions ABB has supplied body shop solutions for complete body Thanks to a close cooperation with Renault, Supplied to a Neyr plant in France, which includes
to produce underbody parts, cross-members, etc framing and for the assembly of underbody components, ABB has developed complete robotized solutions for cavity paint distribution and robot application.
at both Spanish and French plants. complete underbodies and body sides. waxing and has also installed sealing applications. Combined with the equipment, ABB has proposed
a system care agreement to support
Parts: Exhaust systems To adapt the paint lines to the new Megane II, the maintenance of the line.
ABB has provided complete assembly shops to French Renault has invested in additional paint equipment
and Spanish plants. such as robots and applicators.
1 US Dollar = 1 Euro

Overview Agenda

Robotics Division
Markets Served
Service offer
Summary

Service offer overview
A partnership for productivity improvement
Parts & Logistics
- Spare Parts Sales
- Repair Centers
- Inventory Management

Performance Services
Contracts
- Full Service contracts
- Total equipment management
Field Services - Automation performance management
- Service Contracts
- Helpdesk & Remote Services
- Field Operations
- Installation & Commissioning

Training Productivity Improvement
Projects
- Product and System Training - Asset Re-Utilization
- Documentation - Productivity Improvement Software
- Consulting

- System Upgrades and modifications

Global Service Organisation - 1500 Employees

Americas 289 Europe - MEA 1056 Asia- Pacific 171

Present in 45 countries - in more than 100 locations

Parts & Logistics

Over 20,000 spare parts available
Upgrade kits
Accessibility 24/7

Inventory management
SmartSpares
PartsOnline

It’s all about the right part at the right
time at the right place

Service Agreements

Offering you measurable results …
…Service Agreement Packages from ABB

• Maintenance Package
Maximize the Mean Time Between
Failures of your equipment
• Response Package
Minimize the Mean Time To Repair
when stoppages do occur
• Warranty Package
Control the Total Cost of Ownership
of your ABB investment

Annual or ABB Service Professional Customer Representative
Multi-year

Case Study – Service Agreement
Veltri Modular, Canada
ABB Solution
A 5 Year Service agreement to include:
Extended Warranty on Parts/Labor
Consignment Parts
Tailored On Site Training and
Training Credits for scheduled courses
24/7 Technical Support Line
Emergency Breakdown “Block of Hours”
Continuous Improvement visits
The Business Need Plant Audits
Veltri Modular in Windsor,
Ontario, Canada wanted a Key drivers & benefits
proactive, cost effective
way to manage their The service contract provides worry free
service support needs. operation of 100+ robots for 5 years
They needed to fix their By improving the skill set of the employees
costs up front and not and the productivity of the manufacturing cells
worry about the paying for Veltri production levels improved and they

each individual service call. now produce a higher quality product
They also wanted advice
on how to continually All new robots for Veltri will now come with
improve productivity an Integrated Service Agreement

Certified Refurbished Robots

Refurbishment programs for customer owned equipment
Large global inventory of used robot systems
Rebuilt to factory specification, using original parts

Our Global Training Centers

Argentina Australia Austria BeNeLux

Brazil Canada China Czech Republic

Denmark Estonia Finland France


Germany India Italy Japan

Korea Malaysia Mexico Norway

Poland Romania Slovakia Slovenia


South Africa Spain Sweden Switzerland

Taiwan Thailand United Kingdom United States

ABB has dedicated, professional training centers located
throughout the world. No other robot manufacturer has made such
a large investment in equipment (over 300 robots) and professional
instructors (over 100) that are dedicated, full-time, to the education

of our customer’s staff.

Overview Agenda

Robotics Division
Markets Served
Service offer
Summary

Serving our customers business needs
Increased Productivity
We help customers improve manufacturing
productivity and energy efficiency. Our
services build on experience from over
160,000 installations

Reduced Operational Costs
Our products and services help customers
minimize project capital costs and lower
“The effort of ABB to ongoing fixed costs
surpass the original
specifications, and their Consistent Process & Product Quality
willingness to assist us to Robots are proven to deliver consistent
get more & more out of the high quality. They can be recruited to roles
system, has been excellent. where skilled staff are hard to find
We asked for an output of 9
parts per minute but the Improved Workplace Health & Safety
system gives us better than ABB's health, safety, security and
11 Helping minute”
parts per customers boost

environmental offerings help companies
productivity while conserving achieve the highest levels of corporate
Colin Thomas, Electrolux
social responsibility
Australia energy.

“We have a passion for robotics”
ABB is committed to being a world leader in
robotics; capable of designing, producing &
delivering the highest quality robots, systems
& service to meet the needs & expectations of
our customers.
Quality will be built in to everything we do
and will be evident each time we deal with our
customers.
Service is a key part of our offer. We will
support our customers with the highest
quality, most responsive organisation in the
“Even in very diverse industries, we see industry.
common challenges - increasing
productivity and quality, keeping pace Technology & innovation are part of our
with competitors, and adding flexibility DNA. We will continue to invest heavily in
to meet rapidly changing consumer R&D to ensure we meet our customers needs
preference. - both today and in the future.

In both traditional and new industries,
ABB robots are busy creating a core
competency in bottom line results.”

Anders Jonsson
Head of Division – ABB Robotics

For more information visit www.abb.com/robotics

Robotics Division Overview Presentation

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