Manufacturing Automation

Flexible Solutions for Production

Manufacturing is a sector with high demands on efficiency, uptime and adaptability. Labour shortages are reducing productivity across the sector. At the same time, manufacturers are dealing with rising maintenance costs, ageing legacy systems, and increasing pressure to comply with evolving regulatory standards.

Manufacturing automation offers a powerful solution, helping businesses enhance efficiency, ensure compliance, and future-proof their operations.

Reduce Labour-Reliance and Bridge Skill Shortages

Industrial automation addresses labour shortages by supporting manual work and improving picking speed and productivity. Automated systems reduce physical effort and take over repetitive tasks, helping fill gaps caused by staff shortages or a lack of specialised skills. This ensures manufacturers can maintain high performance and output, even when labour availability is limited.

Automated Production Logistics from
Incoming Goods or to Outgoing Goods

Intelligent production logistics is the basis for just-in-time and just-in-sequence concepts, especially in assembly workplaces, where an incorrect delivery immediately leads to downtime and incurs high costs. Automatic warehouses and conveyor systems are complemented by mobile robots that can react flexibly to new production structures.

At the chassis manufacturer KW automotive, the task was to implement the entire intralogistics in the form of automated warehouses and modern conveyor technology as well as a Pick-to-Light system (PTL) in the Built-to-Order production, to integrate it into a flexible production structure and to network it with each other.

Track Your Processes With Real-Time Process Monitoring

Real-time process monitoring is a cornerstone of manufacturing automation, enhancing operational efficiency across production environments. By integrating advanced logistics software, manufacturers gain continuous visibility into material flows using real-time data, enabling faster decision-making, reduced throughput times, and fewer errors. This type of factory automation also improves inventory visibility, supporting accurate stock control and enabling Just-In-Time (JIT) operations. Additionally, integrated Warehouse Control Systems (WCS) and barcode scanning offer full traceability of materials and products, ensuring compliance with regulations and improving overall process transparency.

Eliminate Costly Errors and Ensure Product Quality

Manufacturing automation plays a crucial role in improving process consistency and reducing errors. By limiting manual handling, automated systems enhance accuracy and reduce the risk of mistakes. This leads to higher product quality, fewer defects, and more reliable operations—ultimately saving time and reducing the cost of rework.

Software for the Digitalisation of Intralogistics

Software is the key to the transparency and efficiency of your automation systems. Optionally, our systems can be operated with our own StoreWare software or also connected to software solutions from other providers, such as SAP. Our cloud-based solutions Galileo IoT and Galileo Insight provide you with maximum transparency and further improved availability through the use of analytics.

Prime Example of Perfectly Networked Intralogistics

At the GEBHARDT Innovation Center at the Sinsheim site, the GEBHARDT Intralogistics Group presents the perfect interaction of the company's own intralogistics solutions, software and IoT applications to its customers and interested parties. All under realistic storage and order-picking conditions. “To perfectly automate our own warehouse and at the same time pick real customer orders and supply our production is and remains the declared goal of the GEBHARDT Innovation Centre”, explains Marco Gebhardt, CEO of the GEBHARDT Intralogistics Group. The development and production of intralogistics solutions and IoT applications are subject to continuous evolution, which is why the Innovation Centre is also constantly being expanded with new and further developments, such as the KARIS^® AGV or the SimplePick series.

Space Optimisation with High Density Solutions

Factory automation systems are key to optimising space and material flow. Automatic storage and material handling solutions seamlessly connect each step of the process, enabling high-density storage for both products and raw materials. Whether used for buffering or general inventory, these systems maximise storage capacity and free up valuable warehouse space. As a result, manufacturing automation helps reduce waste and improve overall resource efficiency.

Ergonomic Workplaces Achieved Through Automation

Manufacturing automation supports the creation of safer, more ergonomic workplaces by reducing the physical demands placed on employees. Automating repetitive or strenuous tasks allows workers to shift toward higher-value, less physically taxing roles, improving comfort, satisfaction, and safety. This ergonomic improvement not only prevents workplace injuries but also helps reduce absenteeism, particularly in ageing workforces.

Ergonomics Improve Efficiency and Deliver High Quality

You expect the highest quality from your production and logistics environment. Quality stands and falls with the integration of your employees into the logistical processes. Ergonomically optimally adaptable workplaces facilitate daily work and create space and awareness for assuring optimum quality without product defects or incorrect deliveries. Our software products provide additional support.

Automation and digitalisation determine daily activities in intralogistics. In addition to challenges, they offer new opportunities to meet rising levels of competitive pressure and to become even more efficient. Questions about faster delivery times, error prevention, flexible adaptation to performance peaks and the mapping of very different order picking tasks from an ergonomic point of view can be answered in a customer-specific, flexible and scalable way. This was also Leuze’s experience when it came to building its new international distribution centre.

Minimise Downtime and Protect Productivity

Factory automation delivers dependable performance at every stage of production, helping manufacturers avoid unplanned downtime. By ensuring smooth, consistent processes, automation protects productivity and keeps operations running efficiently—minimising costly interruptions that can impact profitability.

Enhance Efficiency and Unlock Growth Potential

New automation technologies are more energy- and cost-efficient than older legacy systems, helping to reduce operational expenses and improve scalability for long-term growth. While the initial investment in modernisation can be significant, automation delivers substantial returns through increased efficiency and the creation of new growth opportunities. Embracing these technologies is essential for scaling operations and staying competitive in today’s fast-evolving market.