Four technological trends will change robotics and factories in seven years

There are now more than 3.1 million robots working in factories – packaging goods, assembling products, monitoring air quality and much more. ‘There is a robotic revolution underway,’ says Daniela Rus, roboticist and director of the MIT Computer Science and Artificial Intelligence Laboratory, in her new book, “The Heart and the Chip: Our Bright Future With Robots”, co-written with science writer Gregory Mone. ‘If this revolution is conducted correctly and intelligently, intelligent machines have the potential to improve the quality of human life as dramatically as the plough,’ they write.

In Rus’ opinion, robots can give humans “superpowers”. Take our sight, hearing, touch and even smell to distant places and experience those places in a more visceral way. The possibilities are endless and endlessly exciting. ‘What we choose to do with them will define their impact and value. And we can choose to do incredible things.’

What robotics has achieved in the last decade is impressive, but what we’re set to do in the next 20 years is even more exciting, according to Ros. In fact, we’re just getting started. Today, robots can already be built to perform specific tasks repeatedly with phenomenal precision. But even the most advanced robots still don’t cope so well with uncertainty or unforeseen changes. And that has a lot to do with the technologies used to build them:

• robotics – which puts computing in motion by giving a computer system a physical, mobile body. Imagine your smartphone with wheels, wings or even a hand.

• artificial intelligence – which enables them to make decisions in very specific and focussed areas. At the moment, for example, researchers are using Generative AI and other techniques to teach robots new skills – including tasks they could perform in homes.

In the coming years, the robot sector is expected to expand dramatically. By 2030, there could be millions of robots in operation around the world, replacing millions of human jobs, according to some forecasts.

Main trends

These technological advances mentioned above, combined with changing industrial demands, have led major suppliers to see four main trends that will redefine the features and functions of robots in manufacturing over the next six to seven years.

1. AI-powered autonomous robotics: The rapid advance of AI technologies such as machine learning and machine vision has the potential to revolutionise robotics. A great example is Siemens’ SIMATIC Robot Pick AI, a pre-trained deep learning vision software that simplifies part selection for traditional robots, eliminating the need for task-specific software. AI-based adaptability will also help cobots become more aware of their environments, making them increasingly competitive in many sectors.

2. Human-robot partnership: With advances in intelligent mechatronic elements and motion control hardware and software, collaborative robots and exoskeletons can improve the physical capabilities of human workers and relieve tension. In addition, advanced AI and sensor technologies will allow robots to genuinely collaborate with humans and even learn from them.

3. Intuitive, human-centred interfaces: Advances in natural language processing and machine learning are transforming how robots execute commands, further enhancing collaboration. Inspired by large language models, future interfaces will feature intuitive and conversational inputs that simplify programming tasks. Generative AI innovations such as Industrial Copilot will allow engineers and shop floor workers to interact with robots through coding and natural language, making robotic systems more accessible and easier to integrate into daily operations.

4. Virtual training and operation of robotic systems: Digital twins, advanced connectivity, virtualisation and software-defined automation can transform robotic training and operations. These technologies enable virtual simulations, allowing robots to be refined and trained digitally, which reduces costs and risks before real-world deployment. Software-defined automation guarantees adaptability through dynamic updates. Remote operation from virtual, centralised control rooms improves global resource management and safety, especially in hazardous environments. Looking to the future, the industrial metaverse offers the potential for even more immersive interaction with robotic systems, representing the ultimate convergence of these advances.

In Siemens’ opinion, these trends predict a future in which robotic systems will not only be more autonomous, but also perfectly integrated into industrial operations. However, this convergence will manifest itself differently between sectors and their specific processes, depending on the current level of automation.

Industrial domains that are already highly automated today will see greater optimisation and flexibility, for example through software-defined automation, while domains that are still in the early stages – often due to the inflexibility of current systems or the limited tactile capabilities of today’s robotics – are ready for a more pronounced evolution. Over time, this will probably lead to a situation where all sectors converge on a similar level of advanced automation.

These developments and the emergence of advanced, autonomous robotic systems, along with compound innovation in fields such as Extended Reality (XR), AI and digital twins, will have far-reaching impacts. While predicting the exact future remains a challenge – as always – several scenarios highlight the potential of these technologies to transform everything from daily operations on the factory floor to enabling agile and innovative business strategies and revolutionising global supply chains.

1. Your new best friend: robot companions on the factory floor – Imagine walking into a factory where every worker has their own robotic helper. These aren’t clumsy, pre-programmed machines – we’re talking about intelligent, autonomous robots designed to complement human skills perfectly. Here’s what that could look like:

• Robots navigate the shop floor independently, delivering parts and tools exactly when they are needed.
• Vision systems with AI technology help robots identify and retrieve the exact items needed for each task. In hazardous areas such as welding or chemical processing, for example, robots will handle the risky work while humans supervise and make critical decisions.

But it doesn’t stop there. With augmented reality (AR) systems, specialised support can be transmitted from anywhere in the world. A worker encounters a complicated problem and, within minutes, an expert on the other side of the globe sees exactly what they see and offers real-time guidance as if they were right there in the factory. ‘This technology allows us to deploy expertise instantly, anywhere in the world,’ says Maria Chen, Director of Innovation at TechManufacture Solutions. ’It’s like having a team of global experts on call 24/7.’

2. The automation of automation: self-optimising factories – Imagine factories where advanced robotic systems not only manage production, but constantly evolve and improve their own processes. Siemens calls this the ‘automation of automation’, and it’s set to revolutionise industries such as battery recycling.

The main features of these self-optimising factories are:

• Robots efficiently dismantle used batteries, making the process faster, safer and more sustainable.
• The industrial metaverse provides a virtual environment for simulating and perfecting processes before implementation in the real world.
• Software-defined automation allows robots to update their own processes in real time, adapting to new types of products without human intervention. A level of automation that not only increases efficiency, but could reshape global manufacturing.

By automating complex tasks, we can bring production closer to the end markets, reducing dependence on distant supply chains and enabling faster, more responsive manufacturing.

3. Cyber-physical management: where digital meets physical – At the strategic level, advanced robotics acts as the intelligent muscle, translating insights from digital systems into real-world actions. This is where things get really interesting. Imagine a scenario where:

• A digital twin detects a fault in the assembly line process.
• Instantly, the integrated management system updates the programming of the robotic systems to correct the problem.
• The system can also autonomously adjust material orders or change production priorities based on real-time market data.

‘The seamless integration of sensors, IoT, cloud computing and robotics is creating a new paradigm in manufacturing management,’ explains Dr Alex Wong, professor of industrial engineering at Tech University. ‘It’s no longer just about performing tasks – it’s about creating truly adaptable and responsive production systems.’

4. The rise of localised and flexible manufacturing ecosystems – Finally, let’s zoom out and look at the bigger picture. The combination of autonomous robotics and advanced communication networks is enabling a shift towards decentralised and localised production. This could have far-reaching impacts on global trade and the economy. How?

• Local factories rapidly transforming digital designs into physical products, customised to local preferences. – On-demand manufacturing reduces logistical burdens and environmental impact.
• Reduced dependence on complex global supply chains increases resilience and aligns with carbon reduction efforts.

‘This shift towards the ‘glocalisation’ of production can promote economic growth and technological innovation in various regions,’ notes Samantha Lee, chief economist at Global Manufacturing Insights. ‘But it also highlights the need for comprehensive workforce training and skills programmes around the world.’

A flexible, automated (even autonomous) production system is the Holy Grail for many manufacturers who want to simultaneously overcome the challenges of increasing product complexity and achieve greater customisation. The ability to quickly switch production from one product to another will be a defining characteristic of companies on the road to unique batch sizes and the highly customisable products of tomorrow. Flexible automation is seen as the key to meeting the needs of tomorrow’s manufacturing industry.

At the centre of this approach is the ability of robotic systems to interact in real time with a network of digital twins and IoT sensors. This connectivity allows robots to turn digital insights into immediate actions on the shop floor, dynamically optimising operations based on predictive and real-time data. This also includes modern development environments so you can quickly create new automation solutions.

Advanced robotics processes have been designed as pillars for the future digital platform, providing essential values such as integrated validation for AI, data analysis using IIoT, virtual commissioning with automation systems and an open application programming interface (API) for almost infinite customisation.

Compared to conventional robots, advanced robots have superior perception, integrability, adaptability and mobility. These improvements allow for faster configuration, commissioning and reconfiguration, as well as more efficient and stable operations. The cost of this sophisticated equipment will decrease as the prices of sensors and computing power fall, and as software increasingly replaces hardware as the main driver of functionality. Taken together, these improvements mean that advanced robots will be able to perform many tasks more economically than the previous generation of automated systems.

What’s more, improving plant structures and processes with digital technologies can increase productivity and flexibility both in the factory and in the supply chain, allowing producers to adjust quickly to changing customer needs.

But beware! As robotics takes on more advanced functions, the development of comprehensive training programmes and partnerships with educational institutions will be key to training employees. To prepare the workforce not only to operate advanced robotic systems, but also to engage in higher-level problem-solving and decision-making processes.