Automation for Flexible Manufacturing

Automation: human-robot interaction with a cobot polishing a component using a gesture-based assistance interface

Reliable quality. Less strain on employees. From lot-size-one onwards.

In the production of small and medium batch-sizes, demands are increasing: higher quality standards, greater product variety and growing cost pressure, all while facing a shortage of skilled labour.

Traditional automation solutions are often too expensive and too inflexible, making them economically viable only for large series.

Intelligent robotic and visual assistance systems make it possible to support manual work steps or reliably take over physically demanding, repetitive tasks – a technology that PROFACTOR has been developing and deploying in real production environments for many years.

This allows processes to be gradually automated, employees to be relieved where it matters most, and both productivity and quality to be sustainably increased.

Intelligent Robotic Systems

Flexible robotics for the partial or complete automation of manual work steps.

Robots perceive the work situation through intelligent sensors and autonomously adjust the process.
Machining and handling operations are carried out reproducibly with consistent quality and can be flexibly reconfigured if necessary.
Employees are relieved of physically demanding or repetitive tasks and can focus on more important activities.
Ideally suited for processes with high product variety or batch-size-one production.

Visual Assistance for Manual Work Steps

Digital support for processes that cannot or should not be automated.

Camera-based sensors and AI-based algorithms recognize and evaluate the situation, even in unstructured work environments.
Employees receive relevant guidance projected directly onto the component or the workstation – like a navigation system for batch-size-one production.
Systems relieve employees, especially during complex workflows or when handling a high variety of products.
Perfectly suited for picking individual parts, assembling components, or performing manual quality assurance tasks.

Technologies

Lightweight Robots

Lightweight robots are ideal for collaboration with humans in the workplace and do not require enclosed robot cells. Thanks to their force-sensitive control, they ensure employee safety while being perfectly suited for processing tasks that require a defined contact pressure, such as grinding, polishing or similar operations.

Automated Image Processing & AI

Depending on the application, industrial cameras and AI-based software algorithms are used to automatically recognize the work situation or the components.

Automated Process Path Generation

Based on the recognition of component geometry using cameras and sensors, the system automatically calculates the required robot paths. Once defined, the process parameters serve as a template and are adjusted automatically.

Digital Projection

By projecting information directly onto the workstation, assemblies or 3D objects, tasks can be performed faster and errors can be avoided. For larger areas, multiple high-performance projectors are used.

Easy Operation

Employees can focus on their work.

Modern technologies for interacting with machines, such as pen input, gesture recognition, or projection-based visualization, enhance productivity while reducing errors and training effort.

Solutions for Flexible Production

Developing the core technology in-house allows us to tailor solutions individually to meet specific customer requirements.

Leichtbauroboter (Cobot) zur automatisierten Verfugung eines Teak-Bootdecks in der Bootsdeckproduktion

Intelligent Robotic Systems for Machining

Robotic systems that autonomously recognize workpieces and the machining situation and calculate and execute robot movements semi-automatically.

Relieves employees and ensures consistent quality.

Short setup times thanks to very simple job input.

Supports a wide range of processes such as polishing, grinding, brushing, painting, gluing, and welding, tailored to your manufacturing environment.

Stäubli-Industrieroboter beim Bin Picking von Metallteilen in einer automatisierten Produktion

Intelligent Robotic Systems for Assembly & Handling

Robotic systems that autonomously recognize components and assembly/handling situations and automatically calculate and execute gripping/joining movements.

Relieves employees from physically demanding, monotonous tasks.

Short setup times thanks to very simple job input.

System layout and gripper technology can be fully adapted to your work situation.

Automatisierung in der Blechfertigung mit visualisierten Prozessschritten wie Biegen, Entgraten und Verpacken

Visual Assistance for Picking

Projection systems visualize information for the employee directly on the component or workstation.

Relieves employees, prevents careless errors, and increases machine utilization.

Visualization data can be used directly from production control systems or CAD.

Automatisierung: Visuelle Assistenz mit Projektionssystem unterstützt Mitarbeiter beim Rüsten von Maschinen in der Produktion

Visual Assistance for Machine Setup

Projection systems dynamically visualize each work step for the employee directly at the setup station.

Shorter setup times, fewer assembly errors, and prevention of machine downtime due to collisions.

Data for visualization can be used directly from production planning or CAD.

Automatisierung: Assistenzsystem erkennt Handbewegung und markiert einen Fehler digital auf einem Bauteil in der Produktion

Fast, Digital Marking

Assistance systems that recognize employees’ natural hand movements on the component and instantly convert them into digital markings.

Markings can be immediately used by transferring them to production control systems, subsequent processes or existing CAD drawings.

Increases efficiency by eliminating media breaks and avoiding analog intermediate steps.

Added Value through Intelligent Robotics and Visual Assistance

Years of experience enable us to provide customized, reliable solutions for your production.

More Efficient Use of Your Employees

Through better information and relief from secondary tasks.

Reliable Manufacturing Quality and Better Ergonomics

Thanks to intelligent robotic systems that take over physically demanding and repetitive tasks.

Flexibility, Cost-Effectiveness, and Suitability for Batch-Size-One

Enabled by very short setup times and semi-automatic process planning.

Application Areas

Selected real-world examples demonstrate the diverse applications of our intelligent robotic and assistance systems:

Automatisierung: intelligentes Robotersystem für automatischen Kleberauftrag und Ausfugen in der industriellen Produktion

Intelligent robotic system for adhesive application and joint finishing

Automatisierung: intelligentes Robotersystem lackiert ein Bauteil automatisch in einer industriellen Lackierkabine

Intelligent robotic system for painting

Visual assistance for machine setup or assembly of components

Visual assistance for picking and sorting cut parts

PROFACTOR, Your Technology Partner

From innovative ideas to industrial implementation.

Requirements, Concept, and Feasibility

After the initial exchange of information, we clarify objectives, requirements, and the manufacturing situation.

If needed, we test the basic feasibility of the planned solution using sample parts in our laboratory.

This creates a shared understanding of the solution concept, along with a rough cost estimate as a basis for the following phases.

Specification, Quotation, and Engineering

Based on feasibility and your specifications, we prepare a detailed quotation.

We develop the solution, test the system in-house, and prepare it for delivery.

Commissioning and Service

After commissioning in your production environment, we validate system performance through acceptance tests, train your employees, and hand over the system for series operation.

Our service team is available to assist with questions regarding operation, maintenance tasks, or system upgrades, ensuring long-term system availability.

Proven Partnerships

Selected customers and partners from joint development and industrial projects.

Current Research Projects

Our technology portfolio is based on a large number of research projects with national and international partners from industry, universities and research institutions.

We combine industry requirements and global trends to develop forward-looking research projects. In this way, we work with our partners to ensure the competitiveness of industrial production.