Who should consider a humanoid robot?

A pilot is particularly useful for teams assessing changing assembly tasks at existing workstations. Fraunhofer IFAM highlights the importance of suitable test environments, giving businesses the opportunity to gain experience with these applications.

Businesses with frequent product changes

If parts, containers or work sequences change, you need to assess which tasks a platform can actually take on at your existing workstations.

Assembly and quality managers

What matters is whether the gripper, part positioning, image processing and fault handling work with your own workpieces — not just with demonstration samples.

Health and safety and integration managers

They assess the task alongside employees, the workstation interfaces and the protective measures required. According to the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA), the risk assessment should also cover the end effector and moving objects.

What matters when buying?

Start by comparing the task with a fixed automation solution. If a humanoid robot is a possibility, define your requirements for parts handling and safety before arranging a pilot at the intended workstation.

Humanoid platform

Worth considering: When several recurring tasks take place at workstations designed for people, and parts or work sequences vary.

Things to weigh up: Every relevant variant needs a tested approach to gripping, movement and fault handling. A human-like form alone does not prove that the platform offers an advantage for your specific process.

Fixed automation

Worth considering: When part positions, tools and work sequences remain stable over time, and a dedicated work area is possible.

Things to weigh up: Moving between workstations may require modifications. A process comparison will show which solution is better suited to the specific task.

Consideration What to check before buying Who should pay particular attention
Variants and workstations Representative part families and handover points in the pilot; the effort involved in switching tasks or workstations. If work sequences and storage locations change, I don’t want to set up the same platform from scratch for every variant. For around 29% of buyers, this process flexibility is a top priority.
Safety and integration Risk assessment for the specific task; responsibilities, safety functions and workstation interfaces. If employees work nearby, I need to be able to make the entire task safe, including the gripper and workpiece. Around 29% of buyers prioritise this integration.
Gripping and inspection Gripper and payload tested with the actual workpiece and movement profile; reliable detection in the intended lighting conditions. When part positions vary, I need solid evidence that handling and a basic visual inspection work with my parts. This ability to perform the task is the main concern for around 24% of buyers.
Operation and service Charging or changeover process, maintenance, software updates and contractual support in the event of faults. After a successful pilot, I need to be able to manage downtime and adjustments during shift work. Predictable operation is the priority for around 18% of buyers.

Which mistakes make implementation harder?

  • Assuming the CE marking approves the assembly workstation

    In Germany, Section 3 of the Ordinance on Industrial Safety and Health requires employers to carry out a risk assessment before using work equipment. This means the specific task and its protective measures must be considered, even when a product is CE marked.

    Start the assessment early and document the safety functions, the responsibilities of the manufacturer and integrator, and the acceptance criteria for the workstation.

    If you only plan protective measures after installation, you may need to modify the workstation and validate the solution again.

  • Confusing process cameras with safety sensors

    A camera used to recognise parts does not automatically perform a safety function. The Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA) describes technical measures for collaborative robots that monitor movements and bring them to a stop in unsafe conditions.

    In your requirements specification, separate recognition and visual inspection requirements from the safety-related functions that need to be verified.

    If the intended perception system cannot support the safety function, you may need additional safety technology and repeat validation.

  • Taking the platform’s payload rating as proof it can handle your parts

    A rated figure doesn’t tell you whether a workpiece can be handled with the intended gripper, centre of gravity and movement profile. According to the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA), the risk assessment should also cover the end effector and moving objects.

    Test representative parts in the planned work area, including variations in position, delicate surfaces, storage locations and fault scenarios.

    Different parts may require other grippers, fixtures or additional testing.

  • Moving straight from a demonstration to live operation

    A demonstration using prepared parts doesn’t show how the platform will handle the variants and faults found at an assembly workstation. Fraunhofer IFAM emphasises the value of suitable test environments for trialling real tasks.

    Agree on a limited pilot with criteria for part coverage, cycle time, fault handling, safety functions and a manual fallback.

    Unplanned adjustments to material flow, lighting and exception handling require additional staff time before regular operation can begin.

Which manufacturers offer relevant platforms?

The platforms below can help you develop a set of requirements. Manufacturer descriptions are no substitute for comparing a platform with your own parts or assessing the intended workstation.

NEURA Robotics

NEURA Robotics describes 4NE1 as a humanoid platform, with options including a wheeled variant and interchangeable forearms.

  • For your initial assessment, ask about a gripping solution for different tasks and which platform variant is the best fit.
  • You’ll need to test its suitability for a specific part family, the required cycle time and workstation safety in the intended application.

Apptronik

Apptronik positions Apollo for manufacturing tasks at existing workstations and around carts, containers and machines.

  • The applications described provide a starting point for defining handovers and material supply in your own process.
  • Check whether Apollo can handle more precise assembly tasks and provide the required interfaces for your intended application.

UBTECH Robotics

UBTECH Robotics presents Walker S1 in connection with tasks in vehicle manufacturing.

  • The industrial tasks described by the manufacturer can help you define requirements for supply and assembly.
  • Use in vehicle manufacturing does not prove that the platform can be applied to other parts, workstations or operating conditions.

Agility Robotics

Agility Robotics describes Digit for industrial material and process flows and lists interchangeable grippers as a feature.

  • The gripper concept gives you a specific point to discuss when considering part changes and integration into your material flow.
  • For flexible pre-assembly, assess parts handling, cycle time and interfaces against the intended task.

Joybuy products on this topic

Relevant products coming soon.

Frequently asked questions about use and safety

Is CE marking enough to use a robot at an assembly workstation?

No. CE marking does not replace the employer’s risk assessment for the specific use. In Germany, Section 3 of the Ordinance on Industrial Safety and Health requires risks to be assessed before work equipment is used. The necessary protective measures for the task and workplace must then be determined.

Can a humanoid robot work alongside employees without a safety fence?

This can only be decided for the specific workstation and task. According to information from the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA), assessments of collaborative robots also cover the end effector and moving objects. Appropriate technical safeguards and any remaining risks must be assessed accordingly.

What should you consider if cameras could capture employees?

If employees can be identified or observed by cameras, you must check the planned processing for compliance with data protection law. If the business has a works council and a technical system is intended to monitor employees’ behaviour or performance, its introduction and use are also subject to co-determination under Section 87(1)(6) of the German Works Constitution Act. Agree the arrangements with the relevant people at your business before the pilot.

Which machinery laws matter for a project spanning 2026 and 2027?

Work with the manufacturer and integrator to clarify which requirements apply to the specific supply of the machine and the project timeline. The German Federal Institute for Occupational Safety and Health refers, among other things, to the German Product Safety Act, the 9th Product Safety Ordinance and Machinery Directive 2006/42/EC. According to the European Union, Machinery Regulation (EU) 2023/1230 generally applies from 20 January 2027.