Applications
Low-Cost Automation
Karakuri and Low-Cost Automation
Built For Your Production Floor
Reduce repetitive strain, cut cycle time, and automate line-side tasks with karakuri systems that use gravity and mechanical motion — no coding, PLCs, or controls required.
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What is low-cost automation
Mechanical Motion Without Controls or Code
Low-cost automation — often called karakuri — uses mechanical motion, gravity, counterweights, and simple cause-and-effect principles to automate repetitive production tasks. When an operator places a part, removes a bin, or completes an action, the system responds mechanically — tilting, lifting, indexing, or releasing without any electrical input.
The result is a production environment where repetitive, ergonomically demanding tasks are handled by the system — and operators can focus on the work that actually requires skill and judgment. IPS low-cost automation systems are integrated directly into flow racks, workstations, and line-side fixtures where they add the most value.
Common Applications
Where Low-Cost Automation Makes the Difference
- Part presentation at point of use
- Ergonomic height adjustment
- Assisted lifting and lowering
- Controlled part release and indexing
- Positioning components for assembly
- Tilt-and-return bin systems
How it works
Three Types of Low-Cost Automation We Build
Every system uses mechanical principles to create reliable, repeatable motion — no programming, no controls complexity, no specialist maintenance required.
Gravity-driven systems
Use the weight of parts or bins to trigger motion automatically. When a bin is removed from the pick face, the system advances the next one forward — no operator input needed.
Counterweight and tilt systems
Balanced mechanical systems that tilt, flip, or reposition parts as weight shifts. Ideal for presenting parts at the optimal ergonomic angle and returning to position automatically.
Assisted motion systems
Lightweight gear reduction or spring-assisted mechanisms that reduce the effort required for lifting, lowering, or positioning — supporting heavier loads without electrical controls.
Why low-cost automation
When Mechanical is Better than Electrical
Traditional automation is powerful — but for many line-side tasks, it’s overbuilt, overpriced, and harder to change when processes evolve. Low-cost automation solves the same problems at a fraction of the cost and complexity.
Low-Cost Automation (Karakuri)
- No programming or controls expertise needed
- Low implementation cost
- Fast deployment — weeks, not months
- Easy to maintain and troubleshoot
- Reconfigurable as layouts change
- No reliance on software or controls
Traditional Automation
- Requires PLCs, programming, and controls
- High capital investment
- Long lead times and commissioning
- Specialist maintenance required
- Difficult to move or reconfigure
- Overkill for simple repetitive task
Built for Your Operation
Integrated Where it Adds Value
The best low-cost automation is targeted. Rather than automating entire cells, IPS designs mechanical solutions for the specific tasks where repetitive motion, ergonomic strain, or inconsistent part presentation are creating problems. Each system is integrated directly into your existing flow racks, workstations, or line-side fixtures — no separate standalone equipment.
Gravity Flow Racks
Workstations
Line-side fixtures
Custom structures
Why IPS
A Complete System, Not Just a Box of Parts
Built on AluPro and Ecoflex
Using a pipe & joint system? Ecoflex is fully compatible. Ready for a step up? AluPro is our premium system built for demanding lean production environments.
Engineered Around Your Cell
No off-the-shelf workbenches. We work from your cell layout, bin sizes, and tooling to design a system that fits your floor exactly.
Turnkey Systems or Components
Need a complete installed system? We deliver it fully assembled, ready to roll into your cell. Prefer to build in-house? Our full component catalog is available to order directly.
Engineering Support Included
Every project includes practical engineering support — structural validation, layout review, and 3D CAD drawings submitted for your approval before anything is built. No extra fees.
How we Compare
Our Systems vs the Alternatives
Not all modular systems are built for lean production. Here’s how IPS stacks up.
Swipe to compare →
  |
  ✓ Best for Lean
|
 T-Slot Aluminum
Extrusion |
 Welded
Steel |
|
|---|---|---|---|---|
| Designed for | Light-duty lean systems | Lean production & material handling | Structural automation | Permanent structures |
| Lean environment fit | Great | Purpose-built | Often overbuilt | Overkill / rigid |
| Strength-to-weight | Moderate | Very High | High | Low (heavy) |
| Reconfigures | Easy | Quick | Slower | Difficult / permanent |
| Installation | Medium | Easy & fast | Tedious hardware | Requires welding |
| Finish & aesthetics | Industrial | Clean / Modern | Industrial | Rough unless finished |
| Corrosion resistance | Coated exterior only | Excellent | Excellent | Needs coating |
| Installed cost | $ | $ | $$$ | $$ |
Installed cost varies by system size and complexity. Contact us for a project-specific quote.
How we work
From First Conversation to Your Production Floor in Three Steps
1. Tell Us About Your Project
Share your layout, sketch, or BOM. Our project managers gather dimensions, bin specs, and cell constraints — and guide you through anything you need.
2. Design and Approval
Our engineers design your system in 3D CAD and submit drawings for your review. Nothing goes into production without your sign-off.
3. Delivery and Installation
Arrives fully assembled. Roll it into your cell and you're running. Most projects delivered in as little as 2-3 weeks.
Build it yourself
Prefer to design and build in-house? We have you covered.
Our full component catalog — frames, connectors, roller tracks, accessories, and casters is available for teams that want to build their own lean systems.
Explore our comprehensive catalog of modular components:
Let's Talk
Get Your Custom Low-Cost Automation Design Started
Share your layout, sketch, or bill of materials and we’ll get started. A lean manufacturing specialist will follow up to discuss your project.
We typically respond within one business day. Your info is never shared.
Not ready to quote?
We’ll send you physical samples of our AluPro and Ecoflex systems so you can see the quality before committing.
Available to verified manufacturing professionals in Canada and the USA.
Our Work
Low-Cost Automation in Production
Every karakuri system is purpose-built — here’s a sample of what we’ve designed and built.
