Manufacturing
Manufacturing automation solutions for intralogistics and internal production processes
In manufacturing environments, fast and reliable material flow is essential to maintaining productivity and competitiveness. Short product life cycles, fluctuating demand and complex production steps place high demands on flexibility, process stability and transparency.
Intralogistics automation enables manufacturers to streamline internal material flow, reduce manual handling and ensure reliable production supply. From incoming goods to line feeding and internal distribution, automated systems help stabilise processes, improve availability and support efficient, scalable operations.
Essential Technologies for Manufacturing Automation
Manufacturing automation must support a wide range of materials, processes and layouts. With tailored system design, these technologies can be adapted to manufacturing plants, warehouses and distribution centres.
Conveyor Systems
Conveyor systems provide reliable and continuous transport of materials across manufacturing processes. They connect storage areas, production lines and shipping zones, ensuring predictable and controlled material flow.
With components such as transfer units, vertical conveyors and accumulation sections, conveyor technology supports a wide variety of load carriers, including containers, cartons and pallets, even in complex production layouts.
Automated Storage and Retrieval Systems
Automated storage and retrieval systems (ASRS), including shuttle, miniload and pallet solutions, enable high-density storage and fast access to raw materials, components and finished goods.
These systems improve space utilisation, support buffering and sequencing processes, and ensure materials are available for production when required.
Picking Systems and Automated Workstations
Goods-to-Person systems and automated workstations support efficient picking, kitting and order preparation in manufacturing environments. Materials are delivered directly to the workstation, reducing walking distances, manual handling and error rates.
These systems improve throughput while supporting ergonomic workplaces and consistent quality across internal logistics processes.
Warehouse Management Systems
Warehouse management and control software provides transparency across manufacturing operations. Real-time data enables tracking of material flow, inventory levels and process performance from goods receipt to production supply and shipping.
Software solutions also support KPI monitoring, process optimisation and integration with higher-level systems such as ERP and production planning tools.
Case Study: Automated Production Logistics from
Incoming Goods or to Outgoing Goods
Efficient production logistics are critical for just-in-time and just-in-sequence manufacturing, particularly in assembly environments where incorrect deliveries can cause immediate downtime and significant costs. To address this, KW Automotive, a leading chassis manufacturer, implemented a fully automated intralogistics solution.
The project scope included the integration of automated warehouses, modern conveyor systems, and a Pick-to-Light (PTL) system within a Built-to-Order production setup. Additionally, mobile robots were deployed to provide flexible material flow, ensuring the system could easily adapt to evolving production structures. All components were networked into a unified, flexible intralogistics system.
Through this advanced automation setup, KW Automotive has significantly increased production efficiency, reduced downtime risks, and created a future-proof logistics environment aligned with modern manufacturing demands.
Case Study: Ergonomics and Automation for Flexible Distribution Logistics
Leuze, a leading sensor technology manufacturer, transformed its international distribution centre with a focus on combining ergonomic workplace design and advanced automation. The project incorporated height-adjustable, ergonomically optimised workstations alongside intelligent software solutions to reduce picking errors and improve process transparency. Flexible conveyor systems and modular automation components ensured the facility could efficiently manage a wide range of order profiles and adapt to fluctuating demand.
As a result, Leuze achieved faster order throughput, lower error rates, and greater operational flexibility - while fostering a safer, more ergonomic working environment for employees.
How to Get Started with Manufacturing Automation
Getting started with manufacturing automation follows a structured, consultative approach:
Initial consultation
We discuss your production requirements, internal logistics processes and short- and long-term operational objectives.
Requirements analysis
Your existing systems, processes and constraints are analysed to develop an automation concept tailored to your facility.
Implementation and scaling
Following solution selection, we support implementation and ensure the automation system integrates smoothly and can scale with changing production demands.
View More Case Studies
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