Manufacturing
What Is Manufacturing Automation?
Manufacturing automation is the use of automated systems, software and intralogistics solutions to optimise material flow and production processes within manufacturing environments. It helps manufacturers reduce manual handling, improve process reliability and ensure efficient production supply.
Automation technologies such as conveyor systems, automated storage and retrieval systems (ASRS) and warehouse software connect incoming goods, storage, transport and line feeding into one efficient workflow. This improves transparency, flexibility and scalability in smart manufacturing environments while helping manufacturers respond to changing demand and increasing production complexity.
Technologies Used in 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 support automated material handling 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, are automated warehouse systems that 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
Picking 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 efficient production 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 Industry 4.0 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 Manufacturing Automation for Flexible 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.
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