Low-Cost Automation for Lean Manufacturing
Improves ergonomics and reduces repetitive motion
Automates simple tasks without PLCs or complex controls
Uses mechanical motion and cause-and-effect principles
Integrates directly into flow racks and workstations
Designed, assembled and supported in Canada
Low-cost automation provides a practical way to improve ergonomics, consistency, and efficiency on the production floor without traditional automation systems. Often referred to as karakuri, these solutions use mechanical motion and simple cause-and-effect to automate repetitive tasks at the line side — eliminating the need for PLCs, pneumatics, or complex controls.
Low-cost automation is commonly integrated into flow racks, workstations, and production fixtures where flexibility and reliability are critical.
Typical Low-Cost Automation Applications
Common applications include:
Part presentation at the point of use
Ergonomic height adjustment
Assisted lifting or lowering
Controlled part release or indexing
Positioning components for assembly
These solutions are frequently applied in line-side, kitting, supermarket, and workstation environments.
Mechanical Motion Systems
Vertical lifting and lowering
Linear positioning
Indexing and step motion
- Manual or assisted height adjustment
Manual and Assisted Motion
Low-cost automation systems may be configured as:
Manual systems, driven by operator input, gravity, or part weight
Assisted systems, where lightweight motors are used to reduce effort or support heavier loads
Both approaches maintain mechanical simplicity while expanding the range of achievable motion.
Integration with Production Equipment
Low-cost automation concepts can be incorporated directly into:
Gravity flow racks
Workstations
Line-side fixtures
Custom production structures
This allows automation to be applied only where it adds value, without redesigning entire cells or introducing unnecessary complexity.
Why Low-Cost Automation?
Compared to traditional automation, low-cost automation offers:
Lower implementation cost
Faster deployment
Easier maintenance and troubleshooting
Greater flexibility for layout changes
Reduced reliance on controls and software
For many production challenges, a mechanical solution is both sufficient and preferable.
Built for Industrial Use
IPS low-cost automation is used in manufacturing facilities where durability, repeatability, and efficiency matter. Our systems are designed to support continuous operation in demanding production environments. We serve all manufacturing industries including automotive, aerospace, furniture, electronics and more.
From Concept to Delivery. How it works:
1. Tell us about your project
Share your layout, sketch, or bill of materials and our project manager will work with you to gather the relevant information to get started including dimensions, elevations and constraints.
2. Design
With your collaboration, our engineers will design and validate a custom racking configuration to suit your exact application and specifications. 3D CAD drawings and renderings will be submitted for your approval.
3. Delivery and Installation
Our team will will deliver your low-low cost automation system fully assembled and turn key. In most cases your flow rack system arrives ready to be installed into your production cell. In some cases, we can deliver it in kitted form for your team to assemble on site.
No welding or painting. No fabrication delays. Fully modular.
Build Your Own Low Cost Automation in House
Prefer to design and build your own flow racks, workstations and lean manufacturing system? IPS can help with that, too.
Explore our comprehensive catalog of modular components:
Discuss a Low-Cost Automation Concept
Tell us about your project — whether it’s a flow rack, workstation, cart, or line-side structure, we’ll work with you to design a solution that fits your operation.
Submit your details or drawings and we’ll evaluate structural requirements, suitability and cost considerations. A project manager will work with you to ensure you’re specifying the right system for the job.
We typically respond within one business day.
Trusted by the World's Best Manufacturers
IPS Material Handling supports some of North America’s leading manufacturers across automotive, industrial, and general manufacturing environments with scalable, modular solutions built for continuous improvement.
We offer two innovative modular systems – AluPro and Ecoflex, so you always know you’re
getting the solution that fits your budget and out performs the competition.
