How to create your very own low-cost automation solution
Previous experience of lean production is a must for Karakuri/LCA projects, along with additional training. Check out whether low-cost automation is already the right solution for you.
Karakuri/LCA – intelligent automation based on gravity and mechanics
Karakuri is a particularly cost-efficient way for you to automate your processes – without needing drives, sensors, electricity or compressed air. Instead, the laws of physics get things moving.
Karakuri/LCA is the ultimate in lean production
item helps you create low-maintenance, efficient and affordable automation solutions based on Karakuri/LCA. Generally speaking, there is no need for electricity, sensors or programming. Low-cost automation can be implemented much faster than conventional automation and can be adapted flexibly. To get started, you’ll need to embrace the lean philosophy and have some creative minds in your team.
An item expert talks about Karakuri/LCA
Stefan Armbruster is a Karakuri/LCA product manager, expert and trainer at item. In this interview, he uses his specialist knowledge to answer important questions about low-cost automation.
Low-cost automation components in the Online Shop
Special equipment for cost-effective automation – the item Online Shop is full of LCA components to get your customised Karakuri application moving.
A video about the Karakuri/LCA principle
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How to create your very own low-cost automation solution
Karakuri/LCA is regarded as the most sophisticated lean production method. It is recommended for larger companies that have already introduced lean manufacturing. Experienced staff can use item components to create a Karakuri/LCA solution far more efficiently compared to developing a traditional automation solution. The associated costs are up to 90 percent lower than those for full automation.
Knowledge as a foundation for Karakuri/LCA
There are four key factors when implementing low-cost automation – you need creative assembly staff, an environment in which they can realise their full potential, a firm grasp of lean production methods and a flexible modular system. You can then implement and adapt low-cost automation solutions efficiently.
Our experts are happy to share their know-how with you. In the free item Academy, you will find online training units about lean production in general and Karakuri/LCA in particular. item also works closely with the CETPM training institute, holding joint seminars about Karakuri/LCA on a regular basis.
The perfect modular system for economical automation
The Lean Production Building Kit System is the ideal basis for flexible factory equipment engineering. With its lightweight components, end-to-end modularity and long-term stability, the system has been developed specifically for the requirements associated with lean production. Thanks to special components, the system also offers perfect support for your Karakuri/LCA project.
For example, moving components need to be linked by cables, chains or threaded rods, and we offer accessories to do just that. A sprocket wheel can transfer the movement of a chain to a Profile Tube, and a Tool Balancer with a synthetic fibre cable can automatically pull moving components back into their starting position.
FAQs relating to low-cost automation
How do Karakuri/LCA and conventional automation differ?
Implementation is much faster with Karakuri/LCA. Compared to a traditional automation solution, a Karakuri/LCA solution usually takes just a few days to set up. The costs involved are only a fraction of those for conventional systems: you generally do not need electrical, pneumatic or hydraulic components, nor do you require electricity. One exception is hybrid Karakuri/LCA. As the staff involved have the relevant knowledge, they can rectify faults themselves: Low Cost Automation therefore reduces maintenance costs and avoids long downtimes.
When is it worth using Karakuri/LCA?
Whenever material handling is involved. For example, you can implement transport processes in intralogistics using Karakuri/LCA bridges. Automatic storage racks, forklifts or corner solutions are also possible. Small load carriers (SLCs) are usually used for goods transport. These SLCs can be rotated, tilted, emptied, lowered, raised, and fed in and out using Karakuri/LCA solutions. Another option is shooter systems for automatic material supply.
What is a typical beginner’s mistake in Karakuri/LCA?
Without proper training, fundamental errors can creep in. For example, the mechanics are often developed first on the basis of a CAD drawing. However, in Low Cost Automation, this approach is counterproductive: what counts most is creativity and experimentation directly on site. For instance, the required incline of a roller conveyor depends on numerous factors. These include the properties of the goods being transported and the positioning of the roller conveyor. Therefore, one should start developing the application directly, based on the goods being transported and a rough sketch of the task.
“A Karakuri solution can be put together in a few days and comes in at a fraction of the cost of a traditional automation solution. What’s more, it involves fewer components, no programming and therefore no expensive specialist expertise. The fact that staff can fix faults themselves results in low maintenance costs. The equipment won’t grind to a halt while everyone waits for the specialists to turn up with a laptop.”
– Stefan Armbruster, a lean expert at item Industrietechnik
More about low-cost automation
Lean Production Building Kit System
Materials for low-cost automation
All Karakuri/LCA components are part of the item Lean Production Building Kit System. Explore the other categories within our system for fast and efficient factory equipment engineering.
Training
Lean production explained in simple terms – training and other options
Online training modules, a white paper and much more besides – explore
lean production training options in various formats at item.
lean production training options in various formats at item.
Project enquiry
Your very own Karakuri/LCA application
If you already have experience of lean production and are ready to take the next step, we look forward to receiving your enquiry and will be happy to give you the skills you need for your Karakuri/LCA project.