A robot assembly for safe operation in a manufacturing setting with humans including a sensor for detecting a human location and human movement is provided. A safety control module providing a boundary of a safety zone area that is associated with the human in a task oriented state that includes a largest possible area in which the human or an associated work object can extend when the human is standing in one location and performing the work task. The human movement and safety zone area location being used to develop a capture set area that includes at least one predictive future safety zone area location. Using the at least one predicted future safety zone area, establishing a travel path for moving the robot between locations without overlapping the capture set area.