Safe and Compliant Robot Machine Tending with FANUC CRX-10iA/L

Overview

A leading precision manufacturing company sought to improve productivity and reduce operator fatigue in their CNC machining operations. They implemented a robotic machine tending solution using a FANUC CRX-10iA/L collaborative robot (cobot) to automate the loading and unloading of metal components from a CNC milling machine.
Our team was engaged to assess and implement safety measures to ensure the application was both operator-friendly and compliant with international safety standards.

Application Description

The system consisted of:

Robot: FANUC CRX-10iA/L collaborative robot (10 kg payload, 1,418 mm reach)
Task: Loading raw metal blanks into the CNC machine and unloading finished parts
End-of-Arm Tooling: Custom pneumatic gripper with soft-touch jaws to securely handle workpieces
Peripheral Equipment: Machine interface to communicate cycle status, part presence sensors, and a parts staging table
Operation: The robot automatically opens the CNC door, removes the finished component, stages it, loads a new blank, and signals the CNC machine to begin the next cycle.

This setup allowed continuous machine operation with minimal operator intervention, freeing staff for higher-value tasks like quality checks and programming.

Safety & Compliance Challenges

Although the FANUC CRX series is a collaborative robot designed for safe interaction with humans, machine tending introduces additional hazards, including:

Pinch and crush points near the CNC door and workholding fixtures
Sharp edges on machined parts
Unexpected robot motion during machine cycles
The need to integrate safety between the CNC machine and the robot to avoid conflicts

Regulatory compliance required adherence to standards such as:

ISO 10218-1/-2 (Industrial Robot Safety)
ISO/TS 15066 (Collaborative Robot Safety)

Our Role & Implementation

Risk Assessment & Validation

Conducted a full hazard analysis identifying potential pinch, crush, and impact risks.

Measured force and speed limits in accordance with ISO/TS 15066 to confirm safe collaborative operation.

Physical Safeguards

Added safety scanners to detect human presence in restricted zones

Robot automatically reduces its operating speed to safe collaborative limits

Bespoke gripper covers to minimise injury risks from contact.

Safety System
Design

Specified the interlock switches to ensure the robot could not access the spindle area during machining.

Defined safe zones and speed limits using the FANUC CRX’s built-in collaborative features (Power & Force Limiting).

Operator Training & Documentation

Delivered training on emergency stop procedures, safe teaching practices, and routine safety checks.

Provided documentation to support compliance audits.

Key Results and Advantages

✅ Operator Safety & Compliance

The system met ISO/TS 15066 collaborative safety criteria, ensuring safe interaction between workers and the robot.
Risk of injury from the CNC machine and robot was minimised, protecting both personnel and equipment.

✅ Increased Productivity

Continuous machine tending reduced idle time and enabled up to 30% more spindle uptime compared to manual loading.
Operators could focus on inspection and process optimization rather than repetitive loading.

✅ Cost Savings

Reduced labour costs by automating a previously manual, high-frequency task.
Less scrap and downtime due to consistent, precise handling of parts.

✅ Flexibility & Ease of Deployment

FANUC CRX’s intuitive drag-and-drop programming allowed quick product changeovers.
Compact footprint and collaborative design minimised the need for large safety fences, saving valuable floor space.

✅ Enhanced Workforce Satisfaction

Operators reported lower fatigue and greater job satisfaction by shifting from repetitive loading to more skilled work.

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