In this study, a smart and affordable system that utilizes an RGB-D camera to measure the exact position of an operator with respect to an adjacent robotic manipulator was developed. This developed technology was implemented in a simulated human operation in an automated manufacturing robot to achieve two goals; enhancing the safety measures around the robot by adding an affordable smart system for human detection and robot control and developing a system that will allow the between the human-robot collaboration to finish a predefined task. The system utilized an Xbox Kinect V2 sensor/camera and Scorbot ER-V Plus to model and mimics the selected applications. To achieve these goals, a geometric model for the Scorbot and Xbox Kinect V2 was developed, a robotics joint calibration was applied, an algorithm of background segmentation was utilized to detect the operator and a dynamic binary mask for the robot was implemented, and the efficiency of both systems based on the response time and localization error was analyzed. The first application of the Add-on Safety Device aims to monitor the working-space and control the robot to avoid any collisions when an operator enters or gets closer. This application will reduced and remove physical barriers around the robots, expand the physical work area, reduce the proximity limitations, and enhance the human-robots interaction (HRI) in an industrial environment while sustaining a low cost. The system was able to respond to human intrusion to prevent any collision within 500 ms on average, and it was found that the system's bottleneck was PC and robot inter-communication speed. The second application was developing a successful collaborative scenario between a robot and a human operator, where a robot will deposit an object on the operator's hand, mimicking a real-life human-robot collaboration (HRC) tasks. The system was able to detect the operator's hand and it's location then command the robot to place an object on the hand, the system was able to place the object within a mean error of 2.4 cm, and the limitation of this system was the internal variables and data transmitting speed between the robot controller and main computer. These results are encouraging and ongoing work aims to experiment with different operations and implement gesture detection in real-time collaboration tasks while keeping the human operator safe and predicting their behavior.

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