Have Questions About Robotics? We’ve Got Answers.
This FAQ page covers some of the most common questions we hear from manufacturers exploring robotic automation. From system integration and safety to ROI and maintenance, we’re here to help you make informed decisions.
These aren’t all the questions we get—we’ll continue updating this page as new topics come up. If you don’t see your question here, feel free to reach out to our team at sales@mcri-us.com. We’re always happy to help you find the right solution.
Adding Robotics – Where to Start Questions
A robotic integrator specializes in designing, installing, and programming robots to seamlessly work within your facility. Integrators like MCRI ensure your robotic system is installed correctly, customized to your needs, and fully operational from day one.
Evaluating the ROI of automation isn’t just about labor savings or increased throughput. While those are important, many companies overlook high-value benefits like improved quality control, inventory optimization, customer satisfaction, and long-term cost stability.
This article explains the difference between the top 5 ROI factors most companies focus on and the often overlooked benefits that can make or break the true value of your automation investment. It also introduces a free ROI evaluation tool that generates a presentation-ready report to help justify your project.
👉 Read the full article: The Overlooked ROI of Automation: What Most Companies Miss
Yes, our team specializes in designing systems that work seamlessly with your current equipment.
MCRI is a FANUC Authorized System Integrator specializing in robotic automation solutions for manufacturing facilities across a variety of industries. MCRI offers design, integration, installation, and support of robotic systems, including palletizing, material handling, and end-of-line solutions.
MCRI designs and integrates robotic systems tailored to the unique needs of industries such as food and beverage, consumer goods, pharmaceuticals, medical devices, logistics, and more.
After each project we develop a case study that explores the customer’s challenges, the solution and the results of the system. These studies include videos and a sequence of operation for the job. Explore the “Case Studies” section of our website for detailed success stories.
Motion Controls Robotics is a FANUC Authorized System Integrator with over 30 years of experience delivering robotic automation solutions to manufacturing facilities across a wide range of industries. This trusted designation means MCRI meets the highest standards of integration quality and has specialized training and deep expertise in FANUC robotic systems.
We offer complete, end-to-end services—from system design and integration to installation, support, and ongoing service. Our solutions include palletizing, material handling, and comprehensive end-of-line automation.
MCRI understands the unique challenges of your industry. We’ve successfully developed and implemented systems for food and beverage, consumer goods, pharmaceuticals, automotive, and logistics.
With a proven track record, extensive industry experience, and the strength of our FANUC partnership, MCRI delivers smart, reliable, and efficient automation systems that help our customers achieve long-term success.
Chasing only the highest ROI project can seem like a smart strategy, but for customers new to automation, it can actually backfire. High-ROI projects are often larger in scope, more complex, and carry more risk, which can be overwhelming for a company with little or no automation experience.
Instead of jumping straight into the biggest possible return, it’s often wiser to start with a smaller, lower-risk project that allows your team to gain experience, build confidence, and create internal buy-in. These “starter” projects can still offer strong returns—just spread across operational efficiency, safety, quality, and long-term scalability—not just immediate cost savings.
By easing into automation, companies are more likely to have a successful deployment, minimize disruption, and set themselves up for larger, higher-impact projects down the line.
The timeline varies depending on the complexity of the system, but MCRI works efficiently to minimize downtime.
Our team collaborates with you to schedule installation during the best time for you – which can be non-operational hours, if needed.
Technical Robotic Questions
Repeatability is consistent because the robot is going back to the same place (X,Y,Z,W,P,R) in its envelope. Accuracy is not consistent because it is typically a calculated position that the robot is moving to. The further away from the robot mastered position the calculated position is the greater the error in position will become. In the FANUC world there are options to make it better like iRCalibration that will run a routine and figure out the exact length of each link (factory lengths are all the same for the same model robot) and update that internal data for a better kinematic solution. Another approach in the FANUC world is a robot with a secondary encoder such as the M800iA/60.
An HMI (Human-Machine Interface) in a robot system is a screen & software that allows operators to interact with and control the robotic system. It provides a user-friendly interface for monitoring, entering product information, adjusting, and troubleshooting robot operations.
Key Functions of an HMI in a Robot System:
- Visual Display & Control – Displays real-time system data, robot status, and diagnostics.
- User Input – Allows operators to start/stop operations, enter new product specs, adjust settings, and troubleshoot errors.
- Process Monitoring – Shows production metrics, cycle times, and efficiency reports.
- Error Handling – Alerts users to system faults and provides troubleshooting guidance.
- Customization & Integration – Our HMI shows your automation processes, integrating with PLCs (Programmable Logic Controllers) and other control systems.
Industrial robots move and perform tasks using a coordinated system of actuators, sensors, and a central controller. At each joint of the robot arm is a servo motor – a motor with a built-in feedback sensor – which the controller precisely regulates to achieve desired angles or positions
By controlling the servo motors, the robot can move its joints with fine precision, resulting in accurate and smooth motion of the arm. Industrial robots are typically designed with multiple axes (degrees of freedom): simple Cartesian robots may have 3 axes for X, Y, Z motion, while more advanced articulated robots have 6 axes (and some designs add a seventh) to allow full three-dimensional positioning and orientation control of the end-effector
A six-axis robot arm, for example, can position its tool anywhere in space and orient it with pitch, yaw, and roll rotations just like a human wrist
The robot’s controller orchestrates these movements by computing the required joint angles for a given target location and sending commands to each joint’s servo drive
This can be based on coordinates given in a Cartesian frame (e.g. an X, Y, Z position and orientation) or taught joint positions. Upon reaching the target position, the robot’s end effector executes the programmed task, such as picking up a part, welding a seam, or assembling components
Thanks to the closed-loop control of servos, industrial robots exhibit high repeatability and adequate precision, meaning they can perform the same motion over and over with minimal deviation
This level of precision and consistency enables robots to carry out tasks reliably and efficiently in applications ranging from material handling and palletizing to painting and surgery.
When we talk about “end-of-line solutions,” we are referring to the automation and equipment used to handle finished products just before they leave the production line. These systems are designed to increase efficiency, improve quality, and reduce manual labor at the final stage of manufacturing.
Common robotics automation for end-of-line solutions include:
- Case packing – Placing products into boxes or trays
- Labeling – Applying barcodes or shipping labels to products or packages
- Palletizing – Strategically stacking finished goods onto pallets for shipping
- Stretch wrapping – Securing loads with film to keep them stable during transport.
- Automated storage or transport – Using conveyors, ASRS, AGVs, and/or mobile robots to move goods to staging or shipping areas
These systems can be customized to handle different products, packaging styles, and production speeds.
Why does it matter?
Automating your end-of-line process can help reduce bottlenecks, cut labor costs, and ensure consistent packaging quality—especially important in high-volume operations.
Follow-up Support
At Motion Controls Robotics, Inc., we know that well-trained operators and technicians are key to maximizing the performance and efficiency of your robotic systems. That’s why we offer hands-on robotics training to help your team build the skills they need to operate, troubleshoot, and optimize FANUC robots with confidence.
Who benefits from our training?
✅ Operators
✅ Technicians/Maintenance
✅ Engineers
Training can be conducted at your facility or hosted at MCRI to minimize disruptions to your production.
See our Training Information.
Yes, Motion Controls Robotics provides comprehensive post-installation support to ensure long-term system performance and reliability. Our dedicated support team is available 24/7/365 to troubleshoot issues and provide fast, effective resolutions.
We utilize advanced tools like Ewon for secure remote diagnostics, allowing us to quickly identify and resolve issues without the need for an on-site visit. When on-site service is necessary, our experienced technicians are ready to assist.
To ensure the highest level of support, we also offer support contracts that provide priority service response and scheduled maintenance options—giving you peace of mind and minimizing potential downtime.
Take a look at this article for a full overview of Our Preventive Maintenance (PM) plan.
Robot Preventative Maintenance
It’s important to understand that both robots and complete systems require routine maintenance at different intervals—daily, monthly, and annually—to keep everything running smoothly. While general maintenance tasks can often be handled internally, professional preventive maintenance is typically recommended once a year to ensure optimal performance and to catch any potential issues early.
Download this example maintenance guide for the FANUC R-1000 series robot.
to see the different types of maintenance needed and the needed intervals.
Spare parts are a critical component of keeping your system running smoothly and minimizing downtime. At MCRI, we build a custom spare parts package specifically for your system. This package includes the components we’ve identified as most essential—either due to wear over time or their importance to overall system operation.
As a FANUC Authorized System Integrator, MCRI receives exclusive spare part discounts, which we pass directly on to you. Our experienced support team is also highly responsive—quickly identifying, sourcing, and shipping the parts you need to keep your operations moving without delay.
General Robotic FAQs We Hear from Customers
In most cases, you do not need to shut down your entire facility. Our team works closely with you to plan installation during off-hours or scheduled downtime. Typically, only the specific production line being automated needs to be temporarily paused. We aim to minimize disruptions and keep your operations running as smoothly as possible during the integration process.
Robotics can significantly reduce your environmental and operational footprint by improving precision, consistency, and efficiency. Automated systems minimize material waste through accurate handling and repeatable processes, reducing product defects and rework. They also help lower energy consumption by optimizing cycle times and operating only when needed. Additionally, robotics can streamline facility layouts—allowing you to do more with less space—and reduce the need for excessive inventory or overproduction. The result is a leaner, greener, and more sustainable operation.
Safety and Compliance
Yes, MCRI systems include advanced safety features and are designed to comply with A3 and OSHA standards. MCRI performs risk assessments and incorporates safety measures such as light curtains, sensors, and barriers.
Cobots are equipped with force-limiting technology to avoid injuries during human-robot interaction. The total system has to be designed for collaborative working.
Robotics FAQs from Kids
The first digitally operated and programmable robot was invented by George Devol in 1954 and was ultimately called the Unimate. This later laid the foundations of the modern robotics industry.
The robots we work with are made in factories and sent to MCRI for us to add the tooling and supporting equipment. Robots consist of a controller, a robot, a teach pendant, servos and safety devices.
Robots can have issues with the software (code) and/or the hardware. We fix them using standard tools for the mechanical/electrical parts and our computers to write the code along with the teach pendant.
Most things in our day to day world were designed for humans. Making a robot look and act like a human makes them easier for us to accept and it can also make them easier to program since we are familiar with how we would do a task. Industrial robots usually do not look like humans because most humans in factories do not work along side them, but that is changing.
Robots can be made to express emotions but they do not actaully “feel” emotions. They are just programmed to express emotions with their moving parts. AI is changing that today in that robots can learn from circumstances and they can be trained to make good guesses as to what they should be feeling in certain scenarios.