Industries / Automotive: production and assembly
Assembly lines supplied just in time, workstations built around the operator
For OEMs, Tier 1 and Tier 2 suppliers working with WCM and TPS: line-side supermarkets and kitting, mizusumashi and milk runs, VDA 5050-compatible AMRs, kanban on KLT per VDA 4902, workstation ergonomics and visual management. Equipment that adapts when the model changes.
The right part at the point of use
Fixed routes, lines always supplied
Automatic shuttles between areas
The line sets the pace
Effortless workstations
5S, lanes and standards
01
Line-side supermarket and kitting
Components reach the point of use in the right sequence: the operator picks the part instead of looking for it.
The problem
Standard line-side shelving, containers picked from the bottom, kits prepared on pallets on the floor: slow picking, errors and motion muda in every cycle.
The solution
Green Frame flow racks and supermarkets with gravity roller tracks and empty-container return, kit dollies with the deck at picking height, and KLT VDA 4500 containers that slide smoothly along the lanes.
Gravity roller conveyors
Flow racks and supermarkets
Wheel tracks, guides and accessories: the full KLT descends toward the operator, the empty one returns with no motors.
RL-KLT container
Smooth base for roller tracks
VDA 4500 standard: runs smoothly on roller tracks and automated warehouses, 2 kanban label holders, 5 sizes.
Dolly Type VII C
Kit at picking height
Raised deck for picking without bending and Easy Lock drawbar for the tugger train; for kits and light components.
Moving elements and karakuri
Movements without motors
Rotating and sliding connectors, pulleys, springs and anti-return devices for chutes, tilting and empty return.
See also: Friction roller for speed control · R-KLT container for heavy components · Green Frame · Lean workstations
02
Mizusumashi and milk run
The tugger train runs a fixed route, drops off full containers and picks up empties: no forklifts between lines.
The problem
Forklifts running one pallet at a time, crossings with pedestrians, lines stopped waiting for material and operators leaving their workstation to restock.
The solution
LiftLiner® K.Hartwall: bays that lift the cart in under 3 seconds and load from both sides, trailers for KLT dollies and arms that unload at the right height at the machine.
LiftLiner
Patented tugger train
Up to 8 carts per round, 1,000 kg per bay; hitches to the electric tractor, including AGVs, and travels at up to 8 km/h.
LL cart
LiftLiner pallet carrier
Pallets, cages or KLT: push it into the bay and the LiftLiner carries it to the line. 1,000 kg, three sizes.
Taxi Liner
3 bays for 600×400 dollies
Take the dolly you need without uncoupling the others and without following a delivery order; up to 2,250 kg per train.
ARZ 750 Armlift
Unloading at the machine
750 kg, deck tilting from +5° to −40° to unload containers ergonomically.
See also: Milk run drawbar assembly · Tugger train and milk run · Lifting arms for tugger train · Guide to dollies, carts and FIFO lanes
03
AMRs and automatic flows between areas
Repetitive shuttles between warehouse, supermarket and line are handled by robots, integrated with factory systems.
The problem
Fixed routes run by hand every shift, carts pushed for hundreds of meters, wire-guided AGVs hard to move when the layout changes.
The solution
PUDU AMR robots that navigate without tapes, QR codes or reflectors, ISO 3691-4 compliant; the T600 Underride supports VDA 5050 to communicate with the fleet manager.
T600 Underride
Under racks and carts up to 600 kg
255 mm high: slides under the carts you already use and lifts them from the center. ISO 3691-4 compliant, supports VDA 5050.
T600
AMR robot up to 600 kg
Hybrid VSLAM + LiDAR SLAM navigation, speed from 0.2 to 1.2 m/s, 12 h of runtime unloaded.
T300L
With lifting module
Drives under dedicated racks and carts, latches on, lifts up to 300 kg and sets them down at the destination.
MP2000
Autonomous pallet truck with AI
Recognizes pallets and free locations and carries up to 2,000 kg between docks, warehouse and line side.
See also: All logistics robots · Autonomous transport · Guide to logistics robots
04
Kanban and heijunka
The card follows the container and returns to the board: you produce and pick only what the line consumes.
The problem
Cards in generic sleeves that fall off the KLTs, improvised boards, leveling done in spreadsheets nobody sees on the shop floor.
The solution
ORGATEX card holders per VDA 4902 for KLTs and Euroboxes, post boxes for return cards and complete kanban boards with Systembox or Cardplan®.
KLT-Snapper
Top loading, VDA 4902
In rigid PVC for KLT containers: change the card quickly and read it with a scanner. 9 colors, 3 sizes.
KAN-Label
Side loading, VDA 4902
Closed on three sides, fits the label holder slots of KLTs and Euroboxes and kanban boards. 9 colors, 3 sizes.
Kanban post box
Return cards
Up to 40 cards per VDA 4902; wall-mounted or magnetic, A6 to A4 sizes.
Kanban Starter Set
Complete kanban board
Whiteboards, Systembox, holders and cards for 200, 300 or 400 cards; mobile on a stand or wall-mounted.
See also: Traffic-light system for Cardplan® · Kanban and heijunka boards · Kanban System · Kanban system guide
05
Workstation ergonomics
Heavy parts at the right height and oriented toward the operator: less strain, fewer muda, more stable cycles.
The problem
Assemblies, wheels, bumpers and subassemblies lifted by hand, operators bending over the bottom of crates and pallets: high ergonomic risk and variable cycle times.
The solution
Electric Work Positioners with interchangeable grippers and mandrels, tilting lift tables for assembly and pallet lifters loaded with a pallet truck.
WP 125
Work Positioner up to 125 kg
Electric, battery-powered: three strokes up to 2,050 mm, 120 mm/s, handle with integrated remote control.
100 kg electric gripper
Gripping the part from the WP
In stainless steel, for parts up to 100 kg; compatible with WP 125 and WP 205. A rotating version is also available.
ART 750 ArmLift
Lift table with tilt
Up to 750 kg, 1,000 × 1,300 mm platform that tilts from +5° to −40° for picking and assembly.
TSLN 1503
Pallet lifter and tilter
Central leg and free space on three sides; loaded with a manual pallet truck and tilts by 40°.
See also: Work Positioner · Grippers · Pallet lifters · Work Positioner guide
06
Visual management, 5S and safety
Lanes, areas and standards readable by anyone entering the shop floor, even with trucks passing.
The problem
Paint lines worn away by trucks, barely visible signs, tools with no fixed place, quality and maintenance data written on sheets that get lost.
The solution
LongLife tapes for high-load lanes, projected signage, 5S stations and magnetic frames for filling in documents directly on the machine.
LongLife Vector
Tape for heavy-load lanes
0.2 mm polyester, widths 50, 75 and 100 mm, also two-colour yellow/black and white/red.
OX-Spot
Projected signs
LED projector that projects signs and routes onto the floor: it does not wear out and stays visible even in low light.
5S cleaning station
Shadow board
Every tool has a fixed place and missing items are spotted immediately; customisable layout.
Magnetic Windows Frame
Documents filled in on the machine
Open center: place it on the sheet, the board or the machine and the operator writes times, maintenance or quality data.
See also: Information boards · MT1 sweeper robot for the shop floor · Floor marking guide · Electronics and electromechanics (ESD areas)
Have an industrial project to develop?
Choose where to start. Or call us: +39 0434 572757.
Robot demo at your site
We bring the robot to your shop floor and you see it working on your own routes.
On-site visit
We come to see your shop floor, flows and spaces, and propose the right solution.