Flexible assembly technology that halves changeover times
You assemble changing components daily and can’t afford to lose a second. Our flexible assembly technology adapts to new variants in a flash, maintains every cycle time, and ensures reproducible precision. This allows you to gain valuable production time and deliver on time.
Why flexible assembly technology is indispensable
In industries like automotive, medical technology, or electronics, assembly processes today must be both automated and adaptable. The increasing variety of variants and the trend towards customer-specific product solutions mean that production lines must respond flexibly. While classic assembly lines are designed for high volumes and stable geometries, flexible assembly technology can react to even the smallest changes in component shape, processing order, or testing scope without sinking into long changeover times.
A flexible assembly solution from gKteso therefore combines several functions in a single, compact cell: singling, positioning, joining, screwing, gluing, testing, marking, and more. All process modules can be individually combined and expanded as needed. This creates a seamless automation solution that plays to its strengths with small and medium batch sizes.
Structure and functionality of the flexible assembly cell AS Integrated
The AS Integrated is the core module of gKteso’s flexible assembly technology. It is designed so that all essential work steps of component assembly can be carried out in a closed and clearly structured setup. The modular design makes it possible to adapt the cell precisely to the customer’s requirements.
Typical components of the cell
- Camera-based component recognition: An optical system detects the geometry, position, and type of the component to be processed. The control system automatically retrieves the appropriate processing program.
-
Pick-and-place robot: This robot grasps the components, positions them, and accurately transfers them to the respective processing station.
Processing modules: Stations for screwing, gluing, pressing, soldering, or laser marking can be freely configured. - Testing technology: Integrated sensors and camera systems check each process step inline for completeness and quality.
- AGV connection: Automated guided vehicles bring raw parts to the cell and remove finished assemblies. This creates a continuous material flow without manual intervention.
Advantages of our flexible assembly technology in everyday production
High system availability
The AS Integrated requires no long changeover phases. Format changes are completed in a few minutes thanks to pre-configured recipes and automatic component recognition. Your line remains productive even if the component range changes daily.
Consistent process quality
Every work step is monitored inline. Faulty assemblies are immediately detected and sorted out. This results in consistently high quality, regardless of the operator.
Low personnel requirement
Manual tasks are largely eliminated. Only control functions or loading outside the cell require employee involvement. With AGV connection, even this step is automated.
Scalability with growing demand
The cell grows with your requirements. Whether additional screwing stations, new testing steps, or further marking techniques – all extensions can be modularly integrated without having to rebuild the existing system.
Space-saving integration into existing lines
Thanks to its compact design, the cell is ideal for retrofitting existing lines or setting up flexible workstation islands. This way, automation can grow step by step.
Typical areas of application
Our flexible assembly technology is used wherever product variants change frequently and at the same time high precision is required:
- Automotive suppliers: Assembly of sensors, sealing modules, actuators
- Medical technology: Manufacture of safety-critical assemblies with 100 percent control
- Electronics industry: Assembling and screwing sensitive assemblies including end-of-line testing
- Aerospace: Assembly of small components with high quality requirements
- Plastics processing: Post-processing, assembly, and laser marking of injection-molded parts
Our services for your automation strategy
At gKteso, you receive not just a machine, but a tailored solution exactly matched to your production requirements.
- Process analysis: We analyze your current assembly processes and show where automation can provide the greatest leverage.
- System design: Together, we define the optimal configuration of your cell, adapted to geometries, batch sizes, and cycle times.
- Individual manufacturing: Each system is planned, manufactured, programmed, and tested in our facility.
- On-site integration: Our experts integrate the cell into your line, commission it, and train your team.
- Long-term service: We support you even after commissioning with maintenance, expansion, and spare parts supply.
Contact
Do you want to make your assembly processes flexible, economical, and future-proof? Discuss your requirements with us. gKteso develops and delivers customized assembly technology for demanding series productions. Use our know-how for your advantage. We personally advise you and show you how flexible automation works today.