Lean Automation with Karakuri
Business challenge
Process Innovation
Sector
Aerospace
Technology or capability
Automation & Robotics
A team from the Manufacturing Technology Centre (MTC) has been working alongside an industrial partner & suppliers to demonstrate the Karakuri technology development through the MUSIC (Manufacturing Unequalled by Sustainable Innovation & Cost) programme; a funded project; funded by the ATI Programme, which is delivered in partnership with the Aerospace Technology Institute (ATI), Department for Business and Trade (DBT), and Innovate UK.
Karakuri is a lean automation approach that eliminates motors, controls, and electrical components, instead harnessing gravity and mass to enable motion. This innovative solution aimed to reduce costs and improve operational efficiency in high-volume manufacturing environments.
In partnership with
Project Challenges
The client sought a lower-cost alternative to traditional automation methods to enhance operator efficiency. While Karakuri works best with fixed variables such as weight and dimensions, the challenge was to test its limits and adapt the technology for variable conditions. Additionally, the project required understanding industrialisation requirements for seamless integration into a live manufacturing facility.
MTC's Solution
MTC conducted extensive research into Karakuri technology, which is rarely used in the UK beyond basic gravity racking. We partnered with a specialist supplier and ran an ideation workshop to define the most suitable approach. After down-selection, our team progressed from concept to detailed design, assembling and commissioning the solution at MTC’s Coventry facility. The first iteration delivered valuable insights, prompting development of a second revision for enhanced performance.
The Outcome
The result was the Karakuri Material Handling System – Rig One. This semi-automated solution efficiently manages batches of boxes without any electrical components, relying solely on gravity and operator input. Designed using an online configurator, the system was cost-effective to build and quick to deploy. While Karakuri offers significant savings, it demands precise mechanical design and careful integration to achieve optimal performance.
Benefits to the Client
• Cost Savings: The Karakuri solution was 65% cheaper than a fully automated alternative.
• Rapid Deployment: Integrated design tools streamlined procurement and assembly.
• Operational Efficiency: Reduced complexity for civil installations and system integration.
• Adaptability: Handles varying box weights (2kg–10kg) and dimensions, exceeding typical Karakuri limitations.
• Strategic Insight: Demonstrated how lean automation can complement advanced systems, supporting the UK’s drive for efficient, scalable manufacturing.