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

Low-cost automation concepts are well suited for tasks that require repeatable motion but do not justify full automation.

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

IPS offers mechanical motion systems that enable controlled movement using manual or lightly assisted gear reduction.

These systems provide a simple and reliable way to introduce motion into production equipment without adding controls complexity.

Typical motion capabilities include:

• Vertical lifting and lowering

• Linear positioning

• Indexing and step motion

• Manual or assisted height adjustment
  
  

Mechanical motion systems can be used independently or integrated into larger production structures.

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.