Ergonomics is a very important aspect of laboratories. Tasks such as sitting at a hood or microscope for extended periods of time can lead to musculoskeletal disorders (MSDs). MSDs affect the muscles, nerves, blood vessels, ligaments and tendons. According to the Bureau of Labor Statistics (BLS), in 2013 MSD cases accounted for 33 percent of all work-related injury and illness cases.
Rather than be in pain, how can we plan to take advantage of robots and automation in the laboratory? The robot in the laboratory will never have ergonomic problems and will also allow scientists to secure more time for collaboration and innovation.
The Basics
Thomas Edison is well known for his many inventions and an amazing 1,093 patents. Most of his inventions were based on an early model of automation of specific tasks. Today, equipment is being designed to increase productivity and reduce the number of repetitive tasks that people need to do. These tasks can be very labor intensive and ergonomically difficult to perform.
Many products on the market today help to reduce this repetition. An example would be utilizing a robot in liquid handling. Traditionally, a person would sit at a bench with a pipette tool and repeatedly transfer liquid media in small amounts. Now, robotic arms are used to complete this task with AI. These robots can adapt to different sizes and techniques and thus, improve efficiency. A large floor mounted robotic instrument can run 24/7, which would greatly increase production.
However, these larger systems have an impact to your lab design layout and planning. Your lab needs to have the flexibility to accommodate larger equipment, such as these robots. A good lab design includes mobile table systems that can be rolled out of the way to accommodate the robot. Some lab designs even need to consider a larger lab module to provide for clearance and safety.
When Should You Automate or Use Robots?
Really the question is: why are you not using automation and robotics in your laboratory?
Here is a list of 5 reasons why you should:
- Triple Bottom Line
- Ergonomics
- Data Integrity and Traceability
- Process Uniformity
- Throughput
The Triple Bottom Line is defined as a framework to evaluate performance in a broader perspective and is based on the social, environmental and financial framework. Social impact is improved in a variety of ways with automation and robotics. Giving time back to the laboratory staff is a benefit that will greatly improve productivity. Likewise, the potential to operate a more sustainable laboratory that can run utilizing less energy can have a positive impact on our environment.
Data Integrity and Traceability can be invaluable when it comes to research and collecting data in the laboratory. You may have heard a news story or seen an article based on research that was affected by poor data. Some of this has been the result of human error. Tracking, data collection and accountability can be enhanced or improved with automation and robotics.
Process Uniformity is enhanced by improved visual inspection. Humans can have difficulty with visual inspections that determine color, shape and size. This, of course, can be affected by fatigue and other factors that require hand/eye coordination. Advances in computer imaging technology can evaluate the inspection almost instantly and in a repeatable fashion.
Throughput is an obvious advantage. Tasks that can take a person all day to complete can now be done in a much shorter amount of time. Robots with intelligent vision can perform tasks without breaks and with more reliability in the data.
Case Study
Many laboratory owners are looking at automation and robotics at the equipment level. Other laboratory owners are considering this for their entire laboratory space. Although the laboratories will be occupied by people, you can envision these labs running on their own, independent from human interaction. Of course, this is the extreme case for automation and robotics, but it does lead to an interesting thought on operating laboratories more sustainably and efficiently.
The International Institute for Sustainable Laboratories (I2SL) is devoted to the principle of sustainable laboratories and related high-technology facilities, from design to engineering to operation. I2SL proactively supports and educates the industry to support sustainable laboratories that consume less energy. With full implementation of automation and robotics, a laboratory can operate within a closed process environment and one that does not require human thermal comfort. This could greatly impact overall energy consumption and create a new model for laboratory sustainability.
QualTex Laboratories is the largest, independent nonprofit testing laboratory in the U.S. for blood and plasma products. The laboratory is FDA and ISO registered, CLIA-certified and an approved and/or accredited testing facility by multiple companies and health ministries worldwide. An automation line was installed to increase production by approximately 10 times. Before the installation, samples were required to be processed with many separate pieces of equipment. This, in turn, required employees to transfer materials by cart or by hand within the facility in an irregular pattern of flow that was inefficient. By installing a new automation line, production throughput was drastically increased. The track line receives the samples and sends them to each piece of equipment based on a bar code system. In addition to this line, a robot is used for delivery and receipt of samples at the end of the line and for storage/retainage as required. In effect, this space does not require human interaction except for routine maintenance and inspections.
Impacts
Generally speaking, costs to implement these strategies can vary greatly. Custom high-end automation equipment can cost $1,000,000 or more, but individually mass-produced equipment made at a significantly lower cost is becoming more of the norm for laboratory equipment. A Tecan type liquid handler, for example, costs only a few thousand dollars. The ability to adapt equipment to existing building conditions is improving as well. Floor flatness and vibration control may have been difficult to obtain with sensitive automation lines, but much of this new equipment can be installed without any special change to the infrastructure of the building.
A typical lab module is 10 to 11 ft-wide depending on the depth of the bench space and the equipment depth. A common and minimal safety clearance in the aisleway is 5 ft. Larger liquid handling stations may be wider than a typical 3 ft.-deep lab table. This means that tables in a back-to-back island configuration could be removed to allow for a deeper robot.
One would think that with the inclusion of automation and robotics, our labs would require less people. However, what we are actually finding is that more people are required for data analysis due to the significant increase in production. Until AI becomes more common, we will also see an increase in office space required for our labs.
The design and planning of your laboratory will be impacted by automation and robotics now and in the future. According to Market Intelligence, the Global Lab Automation Market was valued at USD 3.14 billion in 2017 and is projected to reach USD 4.64 billion by 2025, growing at a CAGR of 5.0% from 2018 to 2025. We can expect the pace of automation and robotics in the laboratory to incrementally increase over time. Will your lab be ready?
Photo: Viewing window for inspections and safety at QualTex Laboratories. Credit: Triggs Photography
Author: Mark Paskanik is a senior architect and laboratory design expert with CRB. He has 20 years of experience programming, planning, and designing research facilities worldwide. With a focus on tested planning principles, Mark uniquely adapts each lab design to support the client’s vision to create a collaborative, efficient and safe environment.