The readiness of occupational health and safety practitioners in the manufacturing industry for collaborative robots

Abstract

This research set out to explore the health and safety (H&S) challenges encountered by occupational H&S practitioners in the manufacturing industry in relation to the implementation of collaborative robots (cobots). As the manufacturing sector evolves through Industry 4.0 and 5.0, cobots are increasingly integrated into production processes to improve efficiency, precision, and workplace ergonomics. However, their introduction also brings novel physical and psychosocial risks, requiring H&S professionals to adapt existing safety practices and frameworks. To investigate these challenges, a qualitative research methodology was adopted. Semi-structured interviews were conducted with eight H&S practitioners actively working in Malta’s manufacturing industry, all of whom had experience with cobots in their operational environments. The data collected was analysed thematically using Braun and Clarke’s framework, allowing the emergence of key themes related to safety technology limitations, procurement practices, employee perceptions, training gaps, evolving risks, and the lack of specific regulatory guidance. The findings revealed that while cobots offer significant operational advantages, they also present safety concerns related to sensor reliability, system failures, cyber threats, and inadequate regulatory frameworks. Practitioners emphasised the need for early involvement in procurement, structured training, and improved communication to address resistance and technostress among workers. Moreover, there is a critical need for updated national legislation and accessible, specialised training to equip H&S professionals for these new demands. The study concludes that successful cobot integration requires a proactive, multidisciplinary approach, embedding safety from the design stage through to deployment. The implications suggest that organisations must invest not only in technology, but also in workforce development and interdepartmental collaboration to ensure that innovation does not compromise worker safety and well-being.