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Why “One-Size-Fits-All” DEI Strategies Don’t Work in Australian Manufacturing

Written by: Akash Hettiarachchi, Melinda Laundon, Penny Williams and Greg Hearn, all based at QUT in the Australian Cobotics Centre’s Human‑Robot Workforce program

International Women’s Day is an opportunity to celebrate progress toward gender equity and to reflect on persistent structural challenges in the workplaces. While many sectors highlight successes in advancing gender diversity, Australian manufacturing continues to struggle with its historically male-dominated image. Gender inequality in manufacturing is widely recognised. Yet the sector often progresses with uniform policies and strategies.

Our recent research, published in Equality, Diversity and Inclusion: An International Journal, challenges this approach by revealing that diversity patterns across manufacturing are far more complex, uneven, and sub-sector specific. This study examines workforce diversity across Australian manufacturing using Australian Census data from 2006 to 2021. By analysing trends in gender, generation, ethnicity, disability and educational qualifications across manufacturing sub-sectors, we show why improving gender equity requires targeted, context-specific strategies rather than generic, sector-wide approaches.

Manufacturing Gender Diversity is Uneven and Complex

Australian manufacturing is often described as male-dominated; however, our analysis reveals significant variations in workforce gender diversity across its sub-sectors. The overall representation of women differs considerably among sub-sectors such as food and beverage manufacturing, machinery and equipment manufacturing, and fabricated metal products. This unevenness raises questions about the success of gender-specific diversity strategies and outcomes in Australian manufacturing. Given the diversity composition differences among sub-sectors, broad, blanket gender diversity strategies are unlikely to be effective. Instead, improving gender equity requires a clear understanding of where women are over-represented, under-represented, or entirely absent. It also requires an understanding of how personal, structural, and occupational patterns differ across various manufacturing sub sector contexts.

True Representation is More than Increasing Participation

One of the key findings from our study is that improving gender equity is not simply about increasing the overall number of women in manufacturing. Women are frequently concentrated in specific roles and occupational categories, with limited representation across many technical and operational jobs on the production floor, compared with administrative functions. A focus on numbers alone does not deliver sustainable or meaningful representation in most needed job roles in operations.

These patterns suggest that recruitment focused strategies, while important, are insufficient. Genuine progress requires deeper organisational attention including job design, skills development, promotion pathways, and workplace cultures that support retention and advancement for equal opportunities of all genders. Gender equity in manufacturing is therefore closely tied to how work is organised and how careers are structured, particularly as roles continue to evolve through automation and digitalisation.

Different Generations and Future Skills

Our research highlights a persistent structural challenge within Australian manufacturing: the significant representation of an ageing workforce, alongside ongoing difficulty in attracting younger workers (particularly young women) into manufacturing careers. Despite numerous government initiatives, this imbalance remains largely unchanged.

Older workers continue to play a vital role, contributing critical operational knowledge, continuity, and deep technical expertise. At the same time, long-term workforce sustainability depends on successfully attracting and integrating younger talent. Compared with other sectors, manufacturing has been less successful in renewing its workforce, creating a growing concern for future labour supply.

These demographic dynamics intersect directly with technological change. As Industry 4.0 technologies, including collaborative robots, reshape manufacturing work, new skill demands emerge, often accompanied by workforce adjustment challenges. In response, some organisations must prioritise reskilling existing employees, while others may need to rethink job design and career pathways to better align with evolving technologies and the expectations of a more diverse future workforce.

From a gender equity perspective, this underscores the importance of expanding access — not only to employment, but also to training, reskilling, and progression opportunities. Without deliberate intervention, technological transformation risks reinforcing existing gender patterns rather than enabling more inclusive manufacturing careers.

Why This Matters for Cobotics and The Future Of Work

From the perspective of the Australian Cobotics Centre’s Human‑Robot Workforce research program, these findings reinforce that workforce diversity is central to successful technology adoption. Collaborative robots are introduced into existing workplaces shaped by workforce demographics, skills and organisational practices.

Manufacturing sub‑sectors with different gender profiles and labour market conditions will experience cobot adoption in different ways. Without inclusive workforce strategies, new technologies risk reproducing existing inequalities. Conversely, when job design and skill development are approached with gender equity in mind, collaborative robotics can support safer, more sustainable and more attractive manufacturing work.

Turning Reflection into Sustained Action

International Women’s Day is a useful moment for reflection, but our research highlights the need for ongoing, evidence‑based action. Gender inequality in manufacturing is well recognised, yet it is often oversimplified. Addressing it requires sub‑sector‑specific strategies informed by data and grounded in the realities of different manufacturing contexts.

At the Australian Cobotics Centre Human-Robot Workforce Research Program, this research informs our work on future skills, job design and workforce readiness. Improving gender equity is not separate from productivity or innovation. Rather, it is integral to building a manufacturing workforce capable of adapting to technological change and supporting the long‑term sustainability of Australian industry.

 

Prototyping Possibility: UTS Students Put the Kinematic Puppet to the Test

In Spring 2025, undergraduate engineering students from the University of Technology Sydney (UTS) partnered with the Australian Cobotics Centre (ACC) to explore an innovative prototyping method for human–robot interaction (HRI). As part of the subject 43019 Design in Mechanical and Mechatronic Systems, student teams built and tested the Kinematic Puppet—a low‑cost, modular robot‑skeleton prototyping tool designed to support rapid experimentation with robot morphology, motion and collaborative behaviour.

The puppet’s design combines 3D‑printed joints with magnetic rotary encoders and PVC linkages, giving users a physically manipulable platform for exploring robot movement and interaction in a way that is accessible, intuitive, and adaptable. The motivation for the kinematic puppet was discussed in a previous ACC article.

Building Capability Through Hands‑On Prototyping

The project offered students rich, applied learning opportunities across mechanical engineering, mechatronics, electronics, CAD, and hands‑on fabrication. Assembling the puppet from provided design files required teams to engage deeply with mechanical design principles while developing practical manufacturing skills. Students then used the puppet to prototype real HRI scenarios, experimenting with robot behaviours, designing custom end‑effectors, and capturing motion data based on their task concepts.

Beyond construction, students were asked to use the puppet to prototype HRI scenarios relevant to ACC partners. This shifted the learning experience from purely technical engineering to a more integrated design research mindset. Teams were encouraged to roleplay interactions, test alternative geometries, capture movement data, and reflect on usability. The result was a deeper understanding of how cobot systems behave not just as mechanisms, but as partners in real work environments research mindset. Teams were encouraged to role play interactions, test alternative geometries, capture movement data, and reflect on usability. The result was a deeper understanding of how cobot systems behave not just as mechanisms, but as partners in real work environments.

Real Benefits for the Australian Cobotics Centre

For the ACC, the project delivered meaningful insight into how the Kinematic Puppet performs as an early‑stage cobot‑prototyping tool. Students worked with the puppet across a variety of task types and skill levels, generating feedback on build complexity, robustness, adaptability, and user experience. This diversity of testing environments and techniques offered the Centre a broad evidence base for understanding the puppet’s value and limitations in practical prototyping settings.

The partnership also produced a range of custom tool attachments, demonstration artefacts, and user reports, helping the ACC shape future iterations of the puppet and refine research questions around embodied prototyping for collaborative robotics. These outputs contribute directly to a forthcoming study on the prototyping tools effectiveness as a design and ideation tool for industry‑relevant cobot applications.

A Model for Meaningful Industry–University Collaboration

The Kinematic Puppet project exemplifies the mutual benefits of embedding authentic industry challenges within university engineering curricula. Students gained hands‑on technical experience, confidence in iterative prototyping, and exposure to real‑world HRI design practices. Meanwhile, the Australian Cobotics Centre accessed high‑value feedback, creative exploration, and a new understanding of how early‑stage tools can support collaborative robot development.

By bringing students into the research process, this project created space for innovation, fresh ideas, and critical evaluation, laying groundwork for future cobot systems that are safer, more intuitive, and more attuned to human needs.

I would like to thank the students for their hard work on this impressive project; Lachlan Scott Rogers, Laila Chamma, Mishoura Rahman, Nicholas Uremovic and Tran Thu Nhan Dang. A video summarising the journey of the students can be seen here: Kinematic puppet for cobot prototyping

 

 

ARTICLE: From Gut Feel to Evidence: Making the Case for Technology Adoption Through Quality Economics

By Munia Ahamed, UTS PhD Researcher, Australian Cobotics Centre

Technology adoption decisions in manufacturing are often characterised by a tension between perceived opportunity and perceived risk. This is particularly true for small and medium enterprises considering investments in collaborative robotics and automated quality systems, where the upfront costs are concrete, but the returns can feel uncertain.

Research consistently identifies this uncertainty as a key barrier. A 2024 UK government review of advanced technology adoption found that financial barriers—particularly difficulties justifying investment decisions due to uncertain returns—ranked among the most frequently cited obstacles for manufacturers [1], [2], [3]. Similar patterns emerge in studies of Australian SMEs, where decision-makers report hesitancy in embracing new technologies despite recognising their potential benefits.
This article argues that one way to address this challenge is through a more rigorous application of quality cost economics—a well-established body of theory that provides frameworks for quantifying the costs of defects, rework, and quality failures. By grounding technology adoption decisions in these frameworks, manufacturers can move from intuition-based decision-making toward evidence-based investment analysis.

The Economics of Quality: Theoretical Foundations
The concept of quality costing has a long history in operations management. Joseph Juran introduced the notion of the “cost of poor quality” in his 1951 Quality Control Handbook, arguing that organisations inevitably pay for quality—either through prevention and detection, or through the consequences of failure. His work established that appraisal and failure costs are typically much higher than prevention costs, suggesting that investment in getting things right the first time yields significant returns.

Philip Crosby extended this thinking in the 1970s and 1980s with his influential argument that “quality is free”. Crosby’s position was not that quality improvement carries no cost, but rather that the price of nonconformance—scrap, rework, warranty claims, lost customers—far exceeds the price of conformance. His research suggested that well-run quality programs could yield gains of 20 to 25 percent of revenues, with the cost of nonconformance reducible by half within 12 to 18 months of systematic effort.

Armand Feigenbaum’s Prevention-Appraisal-Failure (PAF) model provides a useful taxonomy for categorising quality costs. Prevention costs include activities designed to avoid defects occurring in the first place—process design, training, quality planning. Appraisal costs cover inspection, testing, and measurement activities. Failure costs, both internal (scrap, rework) and external (warranty, returns, reputation damage), represent the consequences of quality problems that were not prevented or detected.

In practical terms, this means that spending more on preventing defects upfront usually reduces the overall cost of quality problems later. Failure costs tend to decrease faster than prevention costs increase, so the total quality cost goes down. This insight remains as relevant today as when it was first articulated, and it provides a theoretical basis for evaluating investments in quality-enhancing technologies.

The Economics of Detection Timing
A related concept concerns the timing of defect detection. The 1:10:100 rule, attributed to George Labovitz and Yu Sang Chang (1992), captures the exponential escalation of costs as defects progress through the value chain. In its simplest form, the rule suggests that addressing a problem at its source costs one unit; finding and correcting it later in the process costs ten units; and dealing with it after it reaches the customer costs one hundred units.

While the specific ratios vary by context, the underlying principle is well-supported: defects that escape early detection accumulate additional processing costs, and defects that reach customers incur costs that extend beyond direct remediation to include relationship damage, complaint handling, and potential regulatory consequences.

This principle has direct relevance to technology adoption decisions. Automated inspection systems and vision-guided collaborative robots do not merely accelerate quality checking—they fundamentally alter when inspection occurs. Real-time, in-process detection catches problems before they accumulate downstream costs, shifting the organisation’s quality cost profile in favourable directions.

Barriers to Evidence-Based Decision Making
If the theoretical case for quality investment is strong, why do manufacturers—particularly SMEs—struggle to act on it? The literature identifies several contributing factors.
First, quality costs are often poorly measured. While direct costs like scrap and rework may be tracked, hidden costs—inspection time, schedule disruption, expedited shipping to replace defective goods—frequently go unrecorded. Without accurate baseline data, it becomes difficult to project returns on quality-enhancing investments.

Second, uncertainty about technology performance creates decision paralysis. Studies of SME technology adoption consistently find that decision-makers hesitate when they cannot point to demonstrated results in comparable contexts. This creates a circular problem: evidence is needed to justify investment, but evidence comes from having invested.

Third, competing priorities and resource constraints mean that quality investments must compete with other demands on limited capital. In this environment, investments with uncertain or difficult-to-quantify returns tend to be deferred in favour of more immediately tangible needs.

ROI Calculators as Analytical Tools

One response to these challenges is the development of structured ROI calculators tailored to specific technology investments. When well-designed, such tools serve several functions beyond simply generating a payback estimate.

First, they impose discipline on baseline measurement. To complete the calculator, users must quantify current defect rates, rework costs, and inspection time—data that many organisations have not systematically collected. The process of gathering this information often yields insights independent of any technology decision.

Second, they make assumptions explicit. A good ROI model does not obscure uncertainty; it surfaces it. Users can see what improvement rates are assumed, what cost factors are included, and how sensitive the conclusions are to different inputs. This transparency supports more informed discussion among stakeholders.

Third, they provide a framework for comparing alternatives. By standardising how costs and benefits are categorised, calculators enable like-for-like comparison of different technology options or implementation approaches.

The value of such tools lies not in their precision—all projections involve uncertainty—but in their capacity to structure thinking and ground decisions in operational data rather than vendor claims or general optimism.

Practical Recommendations

For manufacturers seeking to apply quality cost economics and the 1:10:100 principle to their technology decisions, several practical steps can strengthen the quality of investment analysis.
Establish quality cost baselines. Before evaluating any technology investment, spend time measuring what is currently unmeasured: rework hours, scrap rates, inspection time, defect escape rates. Even approximate figures provide a foundation for analysis that intuition cannot.

Map defect origins and detection points. Understanding where in the process problems arise—and where they are currently caught—identifies the opportunities for earlier detection. The gap between origin and detection represents accumulated cost that prevention or earlier inspection could avoid.
Use sensitivity analysis. Rather than seeking a single ROI figure, explore how conclusions change under different assumptions. What defect reduction would be needed for the investment to break even? How does the payback period shift if improvement is 20% less than projected? This approach acknowledges uncertainty while still supporting decision-making.

Consider pilot implementations. Where full-scale investment feels premature, smaller-scale trials with defined metrics can generate context-specific evidence. This reduces risk while building organisational capability and confidence.

The Path Forward
The theoretical foundations for quality cost analysis are well-established, with decades of research supporting the economic logic of prevention over detection and early detection over late. What is often lacking is the practical application of these frameworks to specific technology adoption decisions.
ROI calculators, when grounded in quality economics and used as analytical tools rather than sales devices, can help bridge this gap. They provide a structured means of translating established theory into operational decision-making, replacing intuition with evidence and making the case for investment in terms that resonate with resource-constrained decision-makers.

For Australian manufacturing to remain globally competitive, we need to accelerate thoughtful adoption of collaborative robotics and quality automation. Fact-based decision tools are one contribution toward that goal.

We welcome discussion on this topic. How has your organisation approached the challenge of justifying technology investments? What frameworks or tools have proven useful?

References
[1] Make UK and RSM UK, Investment Monitor 2024: Using Data to Drive Manufacturing Productivity. London, UK: Make UK, 2024.
[2] Make UK and BDO LLP, Manufacturing Outlook: 2024 Quarter 4. London, UK: Make UK, 2024.
[3] UK Government, Invest 2035: The UK’s Modern Industrial Strategy — Green Paper. London, UK: HM Government, Oct. 2024.

 

ARTICLE: Generalizable Interaction Recognition for Learning from Demonstration Using Wrist and Object Trajectories

Learning from Demonstration (LfD) enables robots to acquire manipulation skills by observing human actions. However, existing methods often face challenges such as high computational cost, limited generalizability, and a loss of key interaction details.

This study presents a compact representation for interaction recognition in LfD that encodes human–object interactions using 2D wrist trajectories and 3D object poses. A lightweight extraction pipeline combines MediaPipe-based wrist tracking with FoundationPose-based 6-DoF object estimation to obtain these trajectories directly from RGB-D video without specialized sensors or heavy preprocessing. Experiments on the GRAB and FPHA datasets show that the representation effectively captures task-relevant interactions, achieving 94.6% accuracy on GRAB and 96.0% on FPHA with well-calibrated probability predictions.

Both Bidirectional Long Short-Term Memory (Bi-LSTM) with attention and Transformer architectures deliver consistent performance, confirming robustness and generalizability. The method achieves sub-second inference, a memory footprint under 1 GB, and reliable operation on both GPU and CPU platforms, enabling deployment on edge devices such as NVIDIA Jetson. By bridging pose-based and object-centric paradigms, this approach offers a compact and efficient foundation for scalable robot learning while preserving essential spatiotemporal dynamics.

ARTICLE: Making Cobots Ready-to-Hand: A Compliance Perspective 

Written by Katia Bourahmoune, UTS & Acting Co-Lead Quality Assurance and Compliance program

Heidegger describes an equipment as ready-to-hand when it disappears into practice, when its use is so seamlessly integrated that it ceases to be an object of thought and becomes instead a transparent extension of action. A hammer is not noticed as a hammer when it drives a nail effectively; it is only when it splinters or slips that it becomes it becomes an object of scrutiny, unready-to-hand, with its use questioned. In modern manufacturing, collaborative robots (cobots) occupy an uneasy position between these two states. They promise repeatability, precision, and tireless monitoring, yet they are undeniably still machines to be supervised, audited, and monitored. In compliance and quality assurance, this human oversight of machines is necessary. Afterall, compliance remains the most human part of the hyper-mechanised modern manufacturing process. This is particularly evident in heavily regulated industries like medical device manufacturing, aviation and defence, where errors are measured not only in costs but in lives and national security.

For cobots to become ready-to-hand, they must be genuinely collaborative: partners in the task rather than peripheral machinery. While collaboration in the context of human-robot interaction is hard to define and evolves as the field advances, it is useful to frame it within the level on interaction between a human and a robot. These levels range from co-existence (shared space, individual actions) to co-operation (shared space, human-guided actions), to collaboration (shared space, joint bi-directional actions). Collaboration through this lens implies shared situational awareness, legible intent, and adaptive action: the robot exposes what it “perceives” (vision, force,…), why it is acting (constraints, goals,…), and how humans can adapt, override, or teach. Such interfaces must preserve human agency and skilled technique while reducing ergonomic and cognitive load. In practice, this means adaptive assistance that yields to expert touch, explanations of proposed actions, and workflows that keep responsibility distributed rather than displaced. When collaboration works this way, it does more than improve throughput; it establishes the preconditions for assurance to be intrinsic rather than supervisory. On this foundation, compliance becomes by design: assurance embedded in action, rather than appended after it. Cobots can inspect as they assemble, verify as they position, and generate audit-grade evidence as a by-product of normal operation. Cobots can extend human judgment through continuous monitoring, allowing human inspectors to concentrate on exceptions, interpretation, and continuous improvement.

This human-robot collaboration fundamentally hinges on trust. In production, workers must believe that a cobot will act predictably and safely; in quality assurance, they must also believe that the cobot’s monitoring and record-keeping are accurate and transparent. Research on automation psychology shows the dangers of both extremes: over-trust leads to blind reliance, while under-trust leads to redundancy and disuse. The literature points to several ways for calibrated trust including reliable and predictable performance, timely feedback, options for human override, transparent explanations of decisions, and auditable records tied to actions, and here we emphasise the compliance-critical elements of legibility, traceability, and contestability. Trust, then, is not an abstract sentiment but a design commitment: when cobots make their intentions legible and their decisions contestable, human operators retain meaningful agency in the loop. This keeps human judgment engaged precisely where it adds the most value. In regulated settings, this turns assurance into a shared practice rather than a supervisory afterthought, and it reorients collaboration toward preserving and amplifying human skill rather than displacing it.

Concerns are often raised that automation “deskills” human labour, relegating workers to passive supervision. Cobots designed for compliance offer the opposite prospect. By taking on repetitive inspection tasks, cobots free human expertise for higher-order judgment: interpreting anomalies, adapting processes, and innovating in response to unforeseen conditions. The skill does not vanish; it is re-centred where it matters most. In this way, cobots not only maintain but actively sustain skill, ensuring that human judgment remains the decisive element in compliance.

The Compliance and Quality Assurance program at the Australian Cobotics Centre aims to develop practical tools that specify, monitor and evaluate human–robot collaboration using multi-modality sensing and AI for assessing compliance.

When cobots are truly ready-to-hand, i.e. useful, trustworthy, and engineered for compliance-by-design, they cease to be mere machines and become true collaborators that elevate human skill while making quality an intrinsic property of every human–robot action.

 

Further reading:  

Heidegger, M. (1962). Being and time. In J. Macquarrie, & E. Robinson, (Trans.), New York, NY: Harper & Row. 

Guertler, M., Tomidei, L., Sick, N., Carmichael, M., Paul, G., Wambsganss, A., … & Hussain, S. (2023). When is a robot a cobot? Moving beyond manufacturing and arm-based cobot manipulators. Proceedings of the Design Society, 3, 3889-3898. https://doi.org/10.1017/pds.2023.390  

Hancock, P. A., Billings, D. R., & Schaefer, K. E. (2011). A meta-analysis of factors affecting trust in human-robot interaction. Human Factors, 53(5), 517–527.  https://doi.org/10.1177/0018720811417254  

Carmichael, M. (2023). Can we Unlock the Potential of Collaborative Robots?. Australian Cobotics Centre. https://www.australiancobotics.org/articles/can-we-unlock-the-potential-of-collaborative-robots/  

 

 

ARTICLE: The Art of Mechamimicry: Designing Prototyping Tools for Human-Robot Interaction

When we think about robotics, especially in high, stakes contexts like surgery, we often imagine advanced machines, complex algorithms, and high, tech labs. But sometimes the best way to design the future is with cardboard, PVC pipes, and a bit of puppetry.

In our recent research, presented at DIS 2025, we explored how embodied, low, fidelity prototyping can help bridge the gap between technical development and the lived realities of people who work with robots.

The Challenge

Robotic, Assisted Surgery (RAS) is a complex and dynamic human–robot interaction (HRI) settings. Surgeons rely on tacit, embodied knowledge built up over years of practice. Engineers bring deep technical expertise. Human factors specialists understand the cognitive and ergonomic limits of people in high, stress environments.

But bringing these perspectives together can be challenging, especially early in the design process. Too often, technical development runs ahead of human needs, leaving systems misaligned with real, world practice.

Our Approach: The Kinematic Puppet

To address this, we developed the kinematic puppet: a modular, tangible prototyping tool that allows users to physically “puppeteer” a robot arm without needing code or expensive equipment.

  • Built with 3D, printed joints, rotary encoders, and PVC linkages, it’s reliable, reusable, and reconfigurable.
  • It integrates with virtual simulation, so physical movements can be recorded and replayed as digital twins.
  • It lowers the barrier for surgeons, engineers, and designers to experiment together, making abstract ideas concrete.

Through physically roleplaying it allows participants to test scenarios and explore ideas before committing to costly development.

Putting It to the Test

We trialled the kinematic puppet in a co-design workshop focused on revision hip surgery. Surgeons, engineers, and designers gathered around a low, fidelity anatomical model, simple props, and the kinematic puppet.

Through roleplay and bodystorming, participants experimented with:

  • Ergonomic tool grips (pen, style vs. drill, style).
  • Spatial layouts of surgical environments.
  • Cooperative control methods (e.g. axis locking, haptic boundaries).

Crucially, the kinematic puppet and surgical props helped surface tacit knowledge, things surgeons know through embodied practice but may struggle to articulate. Combined with simulation, we could capture, replay, and analyse these scenarios for further design development.

Key Takeaways

  1. Embodiment matters: In robotics design, haptic feedback, posture, and movement constraints cannot be understood through software alone. Tangible tools make this knowledge accessible.
  2. Hybrid methods are powerful: Combining physical roleplay with digital capture bridges creative ideation and technical precision.
  3. Collaboration is essential: Designers play a key role in facilitating conversations between different stakeholders helping translate knowledge and experience between disciplines.
  4. Low, fidelity ≠ low, value. Sometimes the simplest prototypes spark the richest insights.

Why This Matters Beyond Surgery

Although our case study focused on surgery, the approach has wider relevance. Any domain where humans and robots work together under constraints, manufacturing, logistics, aerospace, can benefit from accessible, embodied prototyping.

By lowering the technical threshold for participation, we can bring more voices into the design of future robotic systems. That means better alignment with real workflows, safer systems, and technology that truly supports human expertise.

A Call to Action

If you’re working in robotics, design, or any field where humans and machines collaborate:

  • Prototype early, prototype tangibly. Don’t wait for polished tech, start with what people can touch, move, and play with.
  • Value tacit knowledge. Invite practitioners to show you, not just tell you, how they work.
  • Think hybrid. Use both physical artefacts and digital tools to capture richer insights.

The future of robotics won’t just be written in code, it will be shaped through the creative, embodied practices that help us design with people, not just for them.

We would love to hear from others: how have you used tangible or embodied methods to explore technology design in your field?

PhD Research Spotlight: Yuan Liu Enhancing Human-Robot Collaboration Through Augmented and Virtual Reality

Integrating collaborative robots (cobots) into human workspaces demands more than just technical precision, it requires human-centered design. PhD researcher Yuan Liu, based at Queensland University of Technology (QUT), is tackling this challenge through her project Enhancing Human Decision Making in Human-Robot Collaboration: The Role of Augmented Reality, part of the Designing Socio-Technical Robotic Systems program within the Australian Cobotics Centre. 

Yuan’s research investigates the co-design and development of immersive visualisation approaches, including Augmented Reality (AR) and Virtual Reality (VR), to simulate, prototype, and evaluate human-robot collaboration (HRC) within real-world manufacturing environments. Her goal is to empower workers and decision-makers to better understand how cobots affect workflows, spatial layouts, and safety, ultimately improving acceptance and performance. 

By leveraging Extended Reality (XR) technologies, Yuan is working to enhance human decision-making before, during, and after cobot integration. Her aim is to create intuitive, interactive systems that help workers anticipate robot actions and develop AR-based design frameworks that optimise collaboration and safety. 

Her project aligns closely with the program’s mission to embed holistic design as a critical factor in the seamless integration of humans and machines. The broader goal is to improve working conditions, increase production efficiency, and foster workforce acceptance of robotic technologies. Yuan’s work contributes directly to these aims by developing a Human-Centred Design Process, AR-driven frameworks and design guidelines that place human experience at the centre of robotic system development. 

A key component of Yuan’s research is her industry placement with B&R Enclosures, where she is conducting fieldwork in their gasket room. Over the course of her PhD, she will spend 12 months on placement, collecting observational data, conducting interviews, and validating her design outcomes. This engagement ensures that her findings are relevant and transferrable to industry.  

The project is structured across several phases. It began with capturing 360-degree video footage of workers performing tasks in the gasket room, followed by detailed analysis of decision-making during these interactions. Yuan then conducted interviews with employees to gather self-reported insights into their decision-making processes. These findings are informing the development of an AR-based design prototype, tailored to enhance human understanding and collaboration with robots. The final phase focuses on knowledge transfer, ensuring that outcomes are shared with industry partners and the broader research community. 

Yuan’s academic journey reflects her interdisciplinary strengths. Before joining the Australian Cobotics Centre, she earned an MSc in Interactive Media from University College Cork (Ireland) in 2022, where she gained expertise in Multimedia Technologies and Human-Computer Interaction (HCI). Her academic path began with a Bachelor’s degree in Urban Planning from Southwest University (China), followed by several years of professional experience in landscape architecture and urban planning. This diverse background informs her approach to research, blending design thinking with technical innovation. 

Her work is supported by a multidisciplinary supervisory team, including Professor Glenda Caldwell, Professor Markus Rittenbruch, Associate Professor Müge Fialho Leandro Alves Teixeira, Dr Alan Burden, and Dr Matthias Guertler from UTS. She also collaborates closely with staff at B&R Enclosures, including Eric Stocker and Josiah Brooks, who facilitate access to the workplace and support her data collection efforts. 

By the end of her project in November 2026, Yuan aims to deliver a framework for understanding human behaviour and decision-making in manufacturing, a human-centred AR design approach for collaborative robotics, and guidelines for designing AR interfaces that optimise human-robot interaction. 

🔗 Read more about Yuan’s project on our website: https://www.australiancobotics.org/project/project-3-3-augmented-reality-in-collaborative-robotics/  

PhD Research Spotlight: Zongyuan Zhang Tackles Contact Tasks with Mobile Robots

PhD Research Spotlight: Zongyuan Zhang Tackles Contact Tasks with Mobile Robots

As part of the Biomimic Cobots program within the Australian Cobotics Centre, PhD researcher Zongyuan Zhang is leading a project that addresses a key challenge in manufacturing: enabling mobile robots to perform high-precision contact tasks, such as grinding, polishing, and welding, on large, arbitrarily placed workpieces in factory environments.

Zongyuan brings a diverse background in robotics to this work. He holds an M.Sc. in Robotics from the University of Birmingham, UK, where he focused on applying deep learning to manipulator force control. His experience spans control system design, mechanical structure design, and participation in a range of innovative robotics projects—including underwater photography robots, driverless racing cars, exoskeleton mechanical arms, dual-rotor aircraft, and remote-control robotic arms—some of which are now undergoing commercialisation.

His PhD project, Contact Task Execution by Robot with Non-Rigid Fixation, investigates how robots with non-rigidly fixed chassis can maintain the accuracy, stability, and adaptability required for industrial contact tasks. These tasks typically demand hybrid force/position control and high contact forces, which are complicated by the mobility and flexibility of the robot’s base.

This research contributes to the Biomimic Cobots program’s goal of developing collaborative robots that mimic human sensing, learning, and manipulation skills. It explores:

  • How a robot mimics human control to execute contact tasks like sanding and grinding.
  • How augmented mobility enables task execution in large, unconstrained spaces.
  • How minimal task-specific programming can be used to adapt to new workpieces and environments.

Zongyuan, based at QUT, is supervised by Professor Jonathan Roberts, Professor Will Browne, and Dr Chris Lehnert, and is working onsite at ARM Hub alongside industry partner, Vaulta. The project with industrial partners concerns the efficient and accurate removal of surface oxides from metallic materials, thereby enabling tighter bonding between metal components. This embedded collaboration ensures his research is conducted in real production environments and remains grounded in the practical needs of Australian manufacturers.

Recent milestones include the:

  • Design and deployment a framework for performing industrial sanding tasks using collaborative robots.
  • Utilisation of sound as a multimodal input to improve the robustness of the sanding process and enhance the cost-efficiency of the robotic system.
  • Exploration of how humanoid robots can achieve high-precision performance in contact tasks.

Check out our website for the latest on his project: Project 1.1 – Contact task execution by robot with non-rigid fixation » Australian Cobotics Centre | ARC funded ITTC for Collaborative Robotics in Advanced Manufacturing

Zongyuan pictured (centre) with ARM Hub’s Technology Lead, Dr Troy Cordie (top picture, L) and Queensland’s Deputy Premier, Minister for State Development, Infrastructure and Planning and Minister for Industrial Relations, Jarrod Bleijie MP. (R)

ARTICLE: Project Introduction: What Is Trust, Really? Rethinking Human-Robot Interaction Through Design

While engineers often focus on functionality and reliability, real-world deployment reveals a deeper challenge: if people feel uneasy, confused, or disconnected when working with robots, adoption falters. This is especially true in manufacturing, where seamless human-robot collaboration is essential for productivity and safety. 

A new strategic project led by Dr Valeria Macalupu, postdoctoral researcher in QUT’s Human-Robot Interaction (HRI) program, aims to address this challenge by exploring how design affordances, such as physical form, materials, and expressive behaviours, can foster trust between humans and robots. Co-funded by the QUT Design Lab, the project is titled “What is trust really? Exploring Rich Interactions and Design Affordances in Human-Robot Interaction through Co-design.” 

Rather than treating trust as a by-product of performance, the project investigates how visual, tactile, and behavioural cues can signal intent, competence, and emotional safety. These cues are often overlooked in traditional engineering approaches but are critical to how people interpret and respond to robotic systems. 

The research will be developed and disseminated through a series of co-design workshops, iterative prototyping, and a public exhibition. The goal is to generate insights into how robots can be designed to feel more intuitive, approachable, and safe. 

For industry, this project offers practical design guidelines to help engineers and developers create robots that are not only functional but also intuitively acceptable to human users. In manufacturing contexts, this could mean smoother integration of collaborative robots, reduced training time, and improved worker satisfaction. 

More broadly, the project contributes to a growing body of research that sees trust not as a by-product of performance, but as a designable quality. By understanding how people interpret and respond to robots through their physical presence, this work supports the development of safer, more empathetic, and more effective robotic systems. 

Across the Centre, our postdoctoral research fellows lead a diverse range of projects, from long-term initiatives to shorter, more focused pieces of work. This latest project from Dr Macalupu exemplifies the kind of strategic, interdisciplinary work that drives innovation and impact across our programs. 

This project is jointly funded by the Australian Cobotics Centre and the QUT Design Lab.  

Read more about the project: Project 2.9: What is trust really? Exploring Rich Interactions and Design Affordances in Human-Robot Interaction through Co-design » Australian Cobotics Centre | ARC funded ITTC for Collaborative Robotics in Advanced Manufacturing

Get in touch with Valeria: v.chira@qut.edu.au   

ARTICLE: Automating Asset Management Tasks in Factory Settings

As the Asset Management Council of Australia emphasizes, effective asset management provides organizations with insights across four critical domains: physical, information, financial, and intellectual assets. When implemented successfully, it enhances decision-making, strengthens operational resilience, and delivers long-term value. This capability serves as a key differentiator between agile, modern factories and slower, fragmented legacy operations.

The next frontier of asset management explores the shift from human-dependent monitoring to autonomous systems—where assets effectively manage themselves.

Under the Australian Cobotics Centre’s (ACC) Quality Assurance and Compliance program, researchers at the UTS:Robotics Institute are advancing this concept through the deployment of Boston Dynamics’ robotic platform, Spot. In this implementation, Spot autonomously navigates industrial environments, constructs a digital map, captures detailed imagery of equipment such as pipes, coils, and panels, and performs inspection tasks without human supervision.

Collaborative robots, or cobots, play a critical role in this evolving landscape. Designed to complement rather than replace human workers, cobots enhance manufacturing resilience by integrating human judgment with machine-level consistency and precision. Studies by [1] and [2] highlight the synergy of cobots and human teams in improving factory adaptability.

In this approach, robots such as Spot undertake detailed inspection routines, while humans execute follow-up tasks—tightening components, initiating repairs, or notifying human operators through shared digital interfaces. A supporting fleet management system, as outlined by [3], enables real-time tracking of cobot performance, usage, and maintenance status, effectively treating each cobot as a digital asset within the broader ecosystem.

In field trials, Spot demonstrated 90 minutes of continuous operation without a battery swap, covering 7.5 kilometers of factory floor—equivalent to 75,000 m². This capacity enables a single robot to replace multiple manual inspection rounds per shift in a typical Australian SME manufacturing facility.

A key innovation in the system is an integrated asset-management dashboard that connects directly to the SPOT’s API. By aggregating live telemetry, annotated inspection imagery, and equipment metadata, the dashboard eliminates the need for manual data entry. During initial deployments, Spot completed multi-kilometre inspection loops and uploaded over 6,000 annotated images per shift, delivering a comprehensive, timestamped view of equipment health. The dashboard’s real-time capabilities position it as a dynamic decision-support tool, advancing the transition from reactive maintenance to proactive, autonomous operations.

This trial represents a foundational step toward scaling autonomous survey robotics across industry. The integration of AI-driven perception, robotic mobility, and collaborative tasking is redefining the asset management paradigm.

The convergence of autonomous robotics, AI-powered vision systems, and collaborative machines signals a fundamental transformation in industrial asset management. Tasks once characterized by manual oversight are becoming intelligent, continuous processes. Initiatives such as those under the Australian Cobotics Centre offer a forward-looking model where factory systems are capable of sensing, interpreting, and responding with minimal human input—enabling safer, smarter, and more resilient operations across the manufacturing sector.

Citation: https://www.nbnco.com.au/blog/the-nbn-project/the-power-of-robotics-to-lift-digital-capability

Text – Asset Dashboard

[1]           J. Pizoń, M. Cioch, Ł. Kański, and E. Sánchez García, “Cobots Implementation in the Era of Industry 5.0 Using Modern Business and Management Solutions,” Adv. Sci. Technol. Res. J., vol. 16, no. 6, pp. 166–178, Dec. 2022, doi: 10.12913/22998624/156222.

[2]           A. R. Sadik and B. Urban, “An Ontology-Based Approach to Enable Knowledge Representation and Reasoning in Worker–Cobot Agile Manufacturing,” Future Internet, vol. 9, no. 4, Art. no. 4, Dec. 2017, doi: 10.3390/fi9040090.

[3]           B. I. Ismail, M. F. Khalid, R. Kandan, H. Ahmad, M. N. Mohd Mydin, and O. Hong Hoe, “Cobot Fleet Management System Using Cloud and Edge Computing,” in 2020 IEEE 7th International Conference on Engineering Technologies and Applied Sciences (ICETAS), Dec. 2020, pp. 1–5. doi: 10.1109/ICETAS51660.2020.9484266.