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Before buying a humanoid robot, require proof that it can perform one defined production task safely, repeatedly and economically at your site. Ask suppliers for measured results under your cycle time, payload, route, shift and exception conditions—not a general demonstration.
The purchase decision should cover application performance, robot and cell safety, contact and fault behavior, uptime, facility changes, cybersecurity, service obligations and total lifecycle cost. Run a site-specific pilot with written acceptance criteria before committing to a rollout.
Start with the job, not the humanoid shape
A humanoid form factor does not establish that a robot is suitable for a manufacturing task. Begin by writing a task specification that another supplier—or a non-humanoid automation system—could answer against. The specification becomes the baseline for demonstrations, pilots, bids and acceptance testing.
Define the material and handoffs
- Identify the exact parts, totes, cartons or tools the system will handle, including dimensions, mass, surface finish, fragility and variation.
- Describe every handoff: where material arrives, where it must be placed, and how a person or another machine presents the next item.
- Record the route, aisle widths, floor transitions, ramps, doors, lifts and workstations involved.
- List people, forklifts, automated vehicles and other robots that share the space.
Set measurable production targets
Specify cycle time, acceptable first-pass success rate, maximum recovery time, planned shifts, breaks, changeovers and expected production days. State whether the robot must work continuously, alternate with a person or perform several tasks in one shift. Include peak demand rather than only an average hour.
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Describe exceptions before the demonstration
Real production includes missing parts, skewed totes, blocked aisles, dropped objects, unexpected people, damaged packaging and upstream delays. Ask the supplier to show how the system detects, stops, reports and recovers from each exception. A smooth scripted pick-and-place sequence is not evidence of production readiness.
Fraunhofer IPA has developed a modular benchmark for application-relevant humanoid evaluation. Its approach is useful because it tests capabilities such as sensing, manipulation, navigation and reaction speed against defined tasks rather than treating a general-purpose demonstration as proof.
Demand measured performance under your conditions
Ask for a test report that identifies the robot configuration, firmware, software version, payload, gripper, lighting, floor, network conditions, operator involvement and test duration. Without those details, a success percentage or cycle-time claim cannot be compared fairly.
Performance evidence to request
- Task success, failure and retry rates over a statistically meaningful run.
- Cycle-time distribution, including slow cases and recovery time, rather than only an advertised average.
- Payload at the required reach, elevation and walking speed, with grip-force and slip evidence.
- Accuracy and repeatability at the actual placement point.
- Walking speed, stopping distance, turning limits and performance on every floor surface in the route.
- Perception performance when parts, labels, lighting or backgrounds vary.
- How the system behaves when a grasp fails, an object is dropped or a route is blocked.
Use an independent measurement model
Fraunhofer IPA’s benchmark covers six areas: basic capabilities; complex capabilities; cleanroom suitability; functional safety; cybersecurity; and energy efficiency. Measurements include particle emissions, outgassing, cleanability, stability on different surfaces, collision force, obstacle detection, failure behavior, battery consumption and power draw. A benchmark result can expose weaknesses and make supplier claims comparable, but it does not certify that a complete installation is suitable for your site.
NIST’s manufacturing robotics work identifies additional comparison dimensions: performance, collaboration, agility, autonomy, safety, ease of implementation, grasping, perception, mobility and human-robot interaction. Use these as headings in a common scorecard when more than one candidate is under consideration.
Ask what safety evidence covers the robot and the application
Safety must be assessed at two levels. The robot is a machine; the installed system is a robot application or cell with fixtures, tooling, software, people, traffic and foreseeable misuse. A supplier’s statement about the robot alone does not validate the integrated cell.
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Request a documented safety package
- Hazard analysis for the intended task, route, tooling and surrounding equipment.
- Safety-function descriptions, performance levels or safety-integrity claims, and validation results.
- Emergency-stop behavior, protective stops, restart rules and safe-state definitions.
- Limits for speed, force, power, reach and contact, with test conditions.
- Foreseeable misuse analysis, including climbing, pushing, carrying, dropping loads and unauthorized access.
- A clear allocation of responsibility for design, installation, integration, validation, training and future modifications.
Understand the current standards landscape
ISO 10218-1:2025 addresses safety requirements for an industrial robot as a machine before integration. ISO 10218-2:2025 addresses industrial robot applications and robot cells. The standards include exclusions that may matter in manufacturing, including hygienic requirements, some severe or hazardous environments, dangerous-material handling and integration with mobile platforms. Do not assume those standards settle every hazard in a humanoid deployment.
TÜV SÜD states that there is currently no fully harmonised standard for humanoid robots as a complete system. Depending on the design, task and market, an assessment may also involve ISO 12100, ISO 13849, IEC 62061, IEC 61508, IEC 62443, EN 50742 and other requirements. Have qualified safety and compliance personnel determine which obligations apply in your jurisdiction; treat a supplier’s list as a starting point, not a universal legal checklist.
As TÜV SÜD’s Benedikt Pulver puts it, “Humanoid robot safety depends on how sensors, mechanics, software, AI and cybersecurity interact.” Ask the supplier to explain those interactions in the actual application, not merely provide component certificates.
Probe contact, balance loss and fault behavior
A manufacturing robot will eventually meet a person, fixture, pallet edge, dropped object or network interruption. The important question is not whether contact is theoretically possible, but what the system measures, how quickly it reacts and what state it enters afterward.
Questions for physical interaction
- What happens when a person enters the robot’s path or reaches into its workspace?
- What are the measured collision forces at different body locations, speeds, postures and payloads?
- Does contact trigger a controlled stop, power reduction, retreat or other defined response?
- Can the robot remain stable while carrying a load, stepping over a transition or being pushed?
- What prevents a gripper from releasing a load onto a person or critical equipment?
Questions for faults and recovery
- How does it respond to a failed camera, force sensor, motor, battery, controller or network link?
- What happens after a protective stop, power loss or emergency stop?
- Can it detect that it has fallen, and how are people protected during recovery?
- Who is allowed to reset faults, and what evidence is recorded?
- What manual recovery procedure is required, and how often must staff practice it?
Fraunhofer’s testing model includes stability, obstacle detection, collision force and failure behavior. Use those categories in your own witnessed tests. In a 2026 evaluation of a Unitree G1 EDU-4 running firmware 1.04, Fraunhofer IPA reported collision-force results above 500 newtons and described them as exceeding pain thresholds permitted by the applicable standard. That figure applies only to the tested configuration and conditions; it is not a general result for humanoid robots.
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Calculate available production time, not headline battery life
Runtime depends on posture, walking, payload, floor friction, speed, sensing, computing and the number of stops. Require data for the task mix you specified, with charging or battery-change time included.
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Runtime questions
- How long can the robot stand, walk, manipulate and carry under the target load?
- What is the power draw in active work, waiting, charging and fault states?
- How long does a full charge take, and can charging occur during planned breaks?
- Can batteries be swapped safely, and what is their expected replacement interval?
- How much scheduled production time is lost to charging, calibration, software updates and recovery?
Fraunhofer IPA reported maximum operating times of 2 hours 49 minutes while standing and 1 hour 49 minutes in a typical standing-and-walking scenario for the tested Unitree G1 EDU-4. These are configuration- and scenario-specific measurements, not a general humanoid benchmark. Convert a supplier’s runtime into available production minutes per shift after every planned interruption.
Check whether the facility can support the system
A robot that works in a laboratory may fail when placed in a busy plant. Walk the proposed route with the supplier and record every environmental assumption.
Site conditions to verify
- Floor flatness, joints, thresholds, ramps, wet areas, dust and surface traction.
- Aisle and doorway widths, turning space, overhead clearance and emergency egress.
- Lighting range, glare, shadows, reflective surfaces and seasonal changes.
- Material presentation, rack heights, fixture tolerances and access to charging space.
- Wireless coverage, network segmentation, latency and behavior during an outage.
- Safety zones, barriers, warning devices and separation from forklifts or other mobile equipment.
- Temperature, humidity, cleanroom requirements, washdown exposure and hazardous-area constraints.
ISO 10218-2:2025 addresses applications and robot cells but excludes some specialized environments and hazards. If the task involves hygiene, dangerous materials, mobile platforms or unusual environmental conditions, ask the safety team what additional assessment is required.
Integration questions
- Which interfaces connect the robot to conveyors, warehouse systems, manufacturing execution systems, programmable controllers and safety controls?
- Who supplies and validates adapters, fixtures, grippers and end-of-arm tooling?
- What data and timing guarantees are required from existing systems?
- Can the robot be isolated from production without stopping the entire line?
- What changes are required to work instructions, staffing, traffic rules and maintenance procedures?
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Humanoid systems combine sensors, AI models, controllers, wireless links, cloud services and remote support. Ask for evidence that the system remains secure and supportable after commissioning.
Cybersecurity questions
- How are user accounts, privileged access, service accounts and remote sessions controlled?
- Are networks segmented, encrypted and logged, and can the customer review relevant logs?
- How are vulnerabilities reported, prioritized, patched and communicated?
- Are software and AI updates tested against the customer’s application before release?
- Can an update be rolled back without losing calibration, programs or safety settings?
- Where are operational data, video, maps and telemetry stored, and how long are they retained?
- What happens if cloud connectivity is unavailable?
Fraunhofer’s benchmark includes vulnerability management, secure lifecycle practices, network security and penetration resistance. Request the supplier’s equivalent evidence, along with a software-support timeline and end-of-support policy.
Define installation, support and repair responsibilities
Get a responsibility matrix before signing. It should name the party accountable for each activity rather than using “supplier support” as a general promise.
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| Area | Questions to put in the proposal and contract |
|---|---|
| Commissioning | Who installs, configures, validates and accepts the robot and cell? |
| Training | Which operators, technicians and safety staff are trained, for how long and to what competency? |
| Remote support | When is remote access permitted, who approves it and what response time applies? |
| On-site service | Where are technicians located, what coverage hours apply and what travel limits exist? |
| Spare parts | Which parts are stocked, what are lead times and how long will they remain available? |
| Software | How often are updates issued, tested, documented and supported? |
| Incidents | Who investigates injuries, near misses, cyber incidents and repeated task failures? |
| Planned downtime | How are maintenance windows scheduled and production losses handled? |
Public material reviewed for this market does not establish universal warranty periods, repair lead times or service-level commitments. Require those terms, exclusions, escalation paths and remedies in writing.
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Compare purchase, lease and Robots-as-a-Service offers using the same time horizon and production assumptions. A low monthly fee can conceal integration work, charging infrastructure, software, supervision or downtime.
Include every cost category
- Robot, gripper, batteries, chargers and safety equipment.
- Site preparation, fixtures, integration, programming and validation.
- Software licenses, cloud services, data storage and cybersecurity work.
- Training, staffing, monitoring, maintenance and spare parts.
- Energy, battery replacement and scheduled downtime.
- Production losses during pilot, commissioning and recovery.
- Contract renewal, price escalation, termination, data export and equipment return.
Agility Robotics announced a Robots-as-a-Service agreement with Toyota Motor Manufacturing Canada on February 19, 2026, after a successful pilot for manufacturing, supply-chain and logistics operations. The announcement did not disclose pricing or contract terms. Treat it as an example of a commercial structure, not a benchmark for what your deployment should cost.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Require a site-specific pilot before scaling
The pilot should resemble production closely enough to expose failures. Agree on the test plan before the supplier arrives so that a successful demonstration cannot be redefined after the fact.
- Freeze the task definition. Record parts, route, payload, cycle time, shifts, people nearby, exceptions and environmental conditions.
- Set acceptance metrics. Define minimum success rate, maximum cycle time, recovery time, safe-stop behavior, available production time and incident thresholds.
- Run representative shifts. Include normal variation, changeovers, breaks, charging, network interruptions and planned maintenance.
- Witness failure tests. Test blocked routes, dropped parts, unexpected people, sensor faults, loss of balance, power loss and communication loss under the approved safety plan.
- Document every result. Capture configuration, firmware, software, payload, test duration, operator interventions and all failures.
- Review safety and cybersecurity. Complete the application risk assessment, validation records, access review and incident procedures.
- Apply the decision rule. Scale only if every critical criterion passes, residual risks are accepted by the responsible authority and the commercial terms match the measured result.
Ask for customer references with comparable tasks and permission to verify their reported results. A reference using a different payload, route or staffing model may not predict your outcome.
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Use one scorecard for every candidate
When two or more systems are available, test them against the same task and operating conditions. A scorecard should show evidence, not just a weighted opinion.
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| Comparison axis | Evidence to record | Decision question |
|---|---|---|
| Task performance | Success rate, cycle-time distribution, retries and recovery time | Does it meet the production target repeatedly? |
| Payload and dexterity | Grip force, reach, load position, object variation and placement accuracy | Can it handle the real material without special presentation? |
| Mobility | Walking speed, turning, floor transitions, obstacle detection and stopping | Can it travel safely through the actual route? |
| Contact and fault safety | Collision tests, safe states, emergency behavior and failure recovery | Are robot and cell risks controlled and validated? |
| Runtime | Work minutes, charging time, battery changes and energy use | How much scheduled production is genuinely available? |
| Integration | Interfaces, site modifications, commissioning effort and operator workload | What must change before production can start? |
| Cybersecurity | Access controls, patching, rollback, logging and data handling | Can the system be operated and maintained securely? |
| Serviceability | Response times, repair process, parts availability and support period | How quickly can a failure be contained? |
| Total cost | All deployment, operating, downtime and exit costs | Does the business case survive realistic assumptions? |
Interpret vendor-reported market evidence carefully
Vendor announcements can show that a deployment exists, but they are not independent guarantees. Agility Robotics reported more than 65,000 hours of operational time for Digit 4 in 2026. It also reported approximately 98% accuracy at a 100,000-tote cumulative milestone at GXO’s Flowery Branch facility. Those figures are vendor-reported and tied to a particular system, task and site.
The same company reported more than $300 million in multi-year customer orders for Digit 5, subject to contractual milestones. That is an order figure, not revenue or unconditional demand. Its September 15, 2026 announcement said Digit 5 early access was expected in the first half of 2027 and general availability by the end of 2027; the announcement also said the product remained in development, with features subject to change and some safety features still in development. Confirm current availability, configuration and safety status directly before relying on those dates.
Independent evidence should be tied to the configuration and task tested. As Fraunhofer IPA’s Simon Schmidt cautioned, “The market is too volatile and opaque to allow for a well-founded assessment and reliable evaluation of humanoids for specific applications.”
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Proceed only when the supplier has demonstrated the defined job, the application risk assessment is complete, site changes are costed, cybersecurity responsibilities are assigned, support terms are contractual and the total cost remains acceptable under realistic uptime assumptions.
- Go: All critical pilot metrics pass, hazards are controlled and validated, operators are trained, and the contract assigns measurable support obligations.
- Conditional go: Non-critical gaps have an owner, deadline, funded mitigation and a clear restriction on production use until closure.
- No-go: The supplier cannot provide measured evidence, safe behavior is unclear, required site changes are unresolved, or the economics depend on unverified performance.
Include non-humanoid alternatives in the same decision. If a fixed robot, mobile manipulator or redesigned workstation can perform the task with lower risk and cost, the humanoid must justify its additional complexity through measured results—not appearance or marketing.
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