Robotics
Robot cells for gripping, transferring, positioning, loading and unloading — wherever it pays off.
Technically, almost anything can be automated. The question is whether it pays off.
Automation & Robotics
ITR develops project-specific automation solutions — and also declines when a manual solution is more cost-effective. The decision is made in the calculation, not in the technology.
1 · The challenge
The decision is rarely made for technical reasons
It is made because something in the operation no longer adds up — not one of these points is a technical question. They are operational problems, and that is exactly where the system design begins.
Throughput and cycle
Manual processes no longer reach the throughput, or cycle times have to come down.People
Skilled workers are missing, staff are to be relieved, heavy or ergonomically unfavorable work is to be eliminated.Quality and verification
Quality fluctuates with the form of the day; production data and traceability are becoming more important.Line integration
Several process steps are to be connected, existing systems modernized or expanded.Around the clock
Processes are to run reliably in continuous operation.Cost-effectiveness
An automation is to pay for itself within a reasonable time.
2 · Engineering considerations
Before robots are discussed, the numbers are run
It is not the automation alone that decides — what is assessed is when it pays for itself economically. Investment costs, personnel costs, production volume and payback period are considered.
On the technical side, production volume, cycle time, workpiece size and weight, part geometry, range of parts, degree of automation, existing systems and space conditions, availability requirement and customer-specific specifications are weighed.
At the beginning stands the assessment of the current state: which steps run manually today, how long they take, where waiting times arise, where quality fluctuates. Only from that does it follow which step belongs automated — and which does not. Often it is not the one you suspect first: a single bottleneck sets the cycle of the whole line.
When we advise against it
- 01
Low production volumes
The effort does not pay off. - 02
Frequently changing products
Every changeover costs setup time. - 03
The manual solution is more cost-effective
Then it remains the right one. - 04
High changeover effort
It eats up the advantage again.
The same axis from both ends: high production volumes speak for an automation, low ones against it. Where your case lies, we tell you before you invest.
3 · The solution concept
No off-the-shelf systems
If the decision depends on production volume, cycle, range of parts and cost-effectiveness, the result cannot be a catalog product. Every solution is designed project-specifically — the areas below are components of a solution, not product families.
Material flow and conveying
Part feeding, buffering, line integration of several processes, palletizing and depalletizing.
Individual automation solutions
Integration into existing production lines when none of the standard tasks fits on its own.
Typical tasks
At the workpiece
Gripping, transferring, positioning, turning.At the machine
Loading and unloading, part feeding, buffering.In the line
Line integration of several processes, palletizing, depalletizing, integration into existing production lines.
Where a system is integrated into an existing production, it is decided at the transfer points, the cycle coordination and the workpiece fixture — at the position and the time in which the component has to arrive at the next station. Because cell, control system and safety technology come from a single source with us, the responsibility for this transfer does not lie between two suppliers.
On the same level lies the connection to higher-level systems. Which data your production control receives from the system, and in which form, is part of the system design just like cycle time and media routing — the interface is defined in the project, not fixed in advance.
4 · The result
A service in its own right and part of complete special-purpose machines
We have carried out automation projects in which no parts cleaning or water jet deburring system of ours was involved. Our core competence is special-purpose machine building — the development of complete special-purpose machines; we integrate automation where it makes technical and economic sense — also as a project in its own right.
Industries
Already realized
Automotive industryAerospaceMachinery manufacturingFood industryMedical devicesElectronicsPharmaceutical industry
A need for automation arises in every production that runs in cycles. The list therefore does not draw a boundary — it names the industries in which systems of ours are installed.
Where automation meets our other services
With us, parts cleaning and deburring systems are loaded and unloaded automatically, integrated into lines and linked up. Automation is thus also the technology that runs through our two core pillars.
Questions and answers
Frequently asked questions about automation
What does automation at ITR deliver?
We develop project-specific automation solutions for robot cells, material flow and conveying, material handling, machine line integration, palletizing and depalletizing. These areas are components of a solution, not product families — in one project several of them interlock.
Which processes can be automated?
At the workpiece: gripping, transferring, positioning, turning. At the machine: loading and unloading, part feeding, buffering. In the line: line integration of several processes, palletizing, depalletizing, integration into existing production lines. We supply all our cleaning machine types with automated loading and unloading.
What triggers an automation decision?
Rarely the technology. Usually: the throughput can no longer be reached manually, skilled workers are missing, quality fluctuates because it depends on the form of the day, cycle times have to come down, process steps are to be linked, heavy or ergonomically unfavorable work is to be eliminated. Not one of these points is a technical question.
When does automation pay off?
When the numbers add up. Before robots, conveyors or cells are discussed, the numbers are run — investment costs, personnel costs, production volume and payback period are considered. On the technical side: production volume, cycle time, workpiece size, part geometry, range of parts, degree of automation, existing systems and space conditions.
When do you advise against automation?
We do not recommend automation when production volumes are low, products change frequently, the manual solution is more cost-effective or a high changeover effort would arise. That, too, is an overall technical and economic assessment — it simply comes out differently. The same axis works from both ends: high production volumes speak for an automation, low ones against it. Where your case lies, we tell you before you invest.
Are there off-the-shelf automation systems?
No. Every solution is designed on the basis of the requirements of the respective project. That is not a limitation, but the consequence of the decision situation: if production volume, cycle, range of parts and cost-effectiveness tip the scales, the result cannot be a catalog product.
Can I get automation without a cleaning or deburring system as well?
Yes. With us, automation is a service in its own right and part of complete special-purpose machines at the same time. We have already carried out automation projects in which no parts cleaning or water jet deburring system of ours was part of the system. Our core competence is special-purpose machine building — the development of complete special-purpose machines; we integrate automation where it makes technical and economic sense, also as a project in its own right.
How does an automation project begin?
With the assessment of the current state: which steps run manually today, how long they take, where waiting times arise, where quality fluctuates, how often the part is picked up. Only from that does it follow which step belongs automated — and which does not. Often it is not the one you suspect first.
Can a system be integrated into an existing line?
Yes. We design material flow and conveying, transfer points, cycle coordination and interfaces for your existing production. Because cell, workpiece fixture, control system and safety technology come from a single source with us, the responsibility for the transfer does not lie between two suppliers.
Can a system be connected to higher-level systems?
In principle yes — the interface is defined in the project. Which data are transferred and in which form is part of the system design, just like cycle time and media routing.
How can I automate my cleaning?
Workpiece part feeding, loading, cleaning, drying and unloading can be automated — we supply all our cleaning machine types with automated loading and unloading. What makes sense is decided by the calculation, not by the technology. At low production volumes or frequently changing products we do not recommend automation.
Which industries do you build automation solutions for?
Already realized: automotive industry, aerospace, machinery manufacturing, food industry, medical devices, electronics and pharmaceutical industry. A need for automation arises in every production that runs in cycles — the list therefore does not draw a boundary, it names the industries in which systems of ours are installed.
Direct contact
AddressITR GmbH powered by Zippel
Hauptstraße 31
93186 Pettendorf
Pettendorf bei Regensburg
Hauptstraße 31
93186 Pettendorf
Pettendorf bei Regensburg
Phone+49 (0) 9409-777 3598
Fax +49 (0) 9409-777 3607
Fax +49 (0) 9409-777 3607
Technically responsible for this page: Fikret Önal — Managing Director