German Road Safety Specialist Optimizes Container-Unloading with Advanced Automation
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German Road Safety Specialist Optimizes Container-Unloading with Advanced AutomationSee all Off-the-Shelf Solutions WEMAS Absperrtechnik GmbH is a leading German provider of high-quality traffic management solutions and safety products designed for road construction and infrastructure projects. The company specializes in the production and distribution of innovative products such as traffic barriers, warning devices, and signage systems that meet stringent safety and regulatory standards. Many of the company´s products require batteries, and therefore WEMAS purchases multiple full containers of batteries every year. The unloading of the heavy battery boxes from the containers used to be a fully manual task with low efficiency, requiring two operators due to the heavy lifting of the boxes. Now, all of this has been replaced by an off-the-shelf complete solution enabled by OnRobot’s user-friendly D:PLOY-platform - offering same-day installation and allowing WEMAS to increase efficiency when unloading the containers. Every year, WEMAS’ factory in Gütersloh, Germany, receives multiple container shipments of batteries that are packed in boxes. Before adopting an automated solution with D:PLOY, unloading these boxes was a labor-intensive process requiring two operators and typically taking two full days to empty a single container. This task was not only physically demanding and repetitive but also had to be completed quickly to minimize on-site container storage costs. Since the arrival of containers at WEMAS’ factory premises occasionally deviates from the planned schedule, unloading the numerous boxes manually required both flexibility and careful coordination. This often means reassigning two operators from their regular tasks at short notice, which inevitably disrupted production workflows and reduced overall efficiency. A Game-Changer for Efficiency: WEMAS Embraces an Off-the-Shelf Solution After Eye-Opening Demonstration from OnRobot WEMAS immediately realized that an Off-the-Shelf palletizing solution powered by D:PLOY was an answer to their problem. “We were immediately impressed and quickly recognized that D:PLOY technology was different to what we had seen before. The palletizing solution was extremely easy to use, which was very important to us”, says i.A. Julian Döring, Head of Materials Management at WEMAS. WEMAS actively seeks innovative technologies at trade fairs to enhance their processes. During the FMB trade fair in Germany they met with OnRobot’s Dutch partner, Just Automate, who demonstrated the groundbreaking capabilities of their off-the-shelf palletizer branded as MoveComponents and powered by D:PLOY. Captivated by its simplicity and efficiency, WEMAS knew this was the solution they had been looking for. For their project, they selected a configuration featuring an OnRobot VGP20 gripper on a Jaka robot to streamline their operations. "There are plenty of options in the market that claim to offer easy palletizing solutions, but once you see a demo, it often becomes clear they don't live up to the promise," says Julian. "With the MoveComponents solution powered by D:PLOY, it was a completely different experience. What was demonstrated to us is exactly what we got—a smooth, same-day installation that delivered on our standars and expectations." A Standard Solution for Rapidly Transforming Manual Labor into Efficiency For Pieter Treffers, CEO at Just Automate, demonstrating the user-friendliness of D:PLOY was effortless. “It was a perfect match between WEMAS and the D:PLOY-powered solution we suggested, and they have been able to transform a time-consuming and labour-intensive manual process into a consistent, reliable system that has significantly accelerated their processes”, Pieter Treffers comments. Thanks to OnRobot’s same-day deployment model, the integration process has been efficient and minimally disruptive, with the solution quickly installed and operational. As a result, the organization has been able to reduce the amount of time containers spend on-site, directly cutting down the substantial hourly costs associated with container storage. Furthermore, by eliminating the need to coordinate operators for this task, WEMAS has not only improved labour efficiency but also allowed personnel to focus on other essential activities, enhancing overall productivity. “As a German manufacturer, we of course do our utmost to deliver on the highest possible level since what we do has a great impact on road and construction site safety”, i.A. Julian Döring comments. “We have grown consistently over the years, and more and more containers loaded with heavy battery boxes have arrived at our factory. It is a real relief that our D:PLOY-powerd Off-the-Shelf solution has been able to eliminate the strenuous manual unloading of the containers. At the same time, we’ve gained significantly improved efficiency with minimal production disruption, which is more than we could have hoped for”, says i.A. Julian Döring. Improving ergonomics In the past, one container operator could unload an entire container in 16 hours but in order to lessen the physical aspect associated with unloading the containers, WEMAS typically allocated two employees at the same time to the task. “Even with two operators, ergonomics weren’t perfect when handling the many heavy boxes. Now, thanks to the complete solution implemented, only one operator is required. We can also very easily do changeovers if the box sizes vary, since we don’t have to do any programming. That is how simple the solution is to use”, Julian Döring comments. Achieving €30,000 Annual Savings thanks to complete solution. All over the world, manufacturers like WEMAS need to optimize production, inventory, and equipment utilization to better meet customer demands and improve profitability, especially for tasks previously considered too complex and expensive to automate. This is where complete off-the-shelf solutions powered by D:PLOY come into play. They are affordable, scalable, and ideal for high-mix production tasks where finding sufficient staffing can be challenging. All D:PLOY-powered solutions offer same-day installation, quick changeovers for new box sizes, and full control of operations. A standout feature of the solutions powered by D:PLOY is the simplicity as no advanced programming skills are needed. It is an off-the shelf complete solution with full price transparency, and it offers straightforward in-house redeployment after an initial setup by one of OnRobot’s regional partners. This is part of the reason why WEMAS found it especially appealing. “Because the solution has helped us unload and subsequently return the containers much faster, we have been able to minimize storage fees, improve our operational efficiency, and achieve a significant overall cost reduction”, Julian Döring adds. “Basically, all we had to do was to deliver electricity and the internet connection to achieve a yearly 30,000 € cost-saving. Even for a highly efficient German company, this is quite an achievement”, he says. Significant new market approach OnRobot has carved out a significant new market approach to collaborative automation for high-mix applications that solves many ongoing labor challenges in ways previously unavailable. Manufacturers like WEMAS can now buy standard, Off-the-Shelf complete applications (such as the MoveComponents palletizer) from trusted regional partners that are flexible, affordable, and can be installed in less than a day. This is exactly what WEMAS needed. “In a company like ours, we’re aiming for full control of our operations, high productivity, quick changeovers if box-sizes shift – and the shortest possible payback time. This is why I believe we simply couldn’t have chosen a better robotics technology than the one powered by D:PLOY”, Julian Döring ends.
About WEMAS Absperrtechnik GmbH WEMAS was originally founded in 1971 as a trading company for tool technology and machines. But already in 1978, the S in the name got a new meaning: road safety technology. At that time, WEMAS was one of the pioneers who developed and produced products for the protection of workplaces and road construction sites and distributed them throughout Germany. The pioneering spirit was followed by many product innovations and the transformation of the portfolio from products manufactured mainly in sheet metal to now include robust, easy-to-handle plastic products. Today WEMAS acts as a full-range supplier and has all necessary legal approvals and certificates. It is the products, production, processes and of course the people that have made WEMAS the market leader it is today - by a clear margin. Continue reading on www.wemas.de/en About OnRobot |
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German Road Safety Specialist Optimizes Container-Unloading with Advanced Automation
WEMAS Absperrtechnik GmbH is a leading German provider of high-quality traffic management solutions and safety products designed for road construction and infrastructure projects. The company specializes in the production and distribution of innovative products such as traffic barriers, warning devices, and signage systems that meet stringent safety and regulatory standards. Many of the company´s products require batteries, and therefore WEMAS purchases multiple full containers of batteries every year. The unloading of the heavy battery boxes from the containers used to be a fully manual task with low efficiency, requiring two operators due to the heavy lifting of the boxes. Now, all of this has been replaced by an off-the-shelf complete solution enabled by OnRobot’s user-friendly D:PLOY-platform - offering same-day installation and allowing WEMAS to increase efficiency when unloading the containers.
Every year, WEMAS’ factory in Gütersloh, Germany, receives multiple container shipments of batteries that are packed in boxes. Before adopting an automated solution with D:PLOY, unloading these boxes was a labor-intensive process requiring two operators and typically taking two full days to empty a single container. This task was not only physically demanding and repetitive but also had to be completed quickly to minimize on-site container storage costs.
Since the arrival of containers at WEMAS’ factory premises occasionally deviates from the planned schedule, unloading the numerous boxes manually required both flexibility and careful coordination. This often means reassigning two operators from their regular tasks at short notice, which inevitably disrupted production workflows and reduced overall efficiency.
A Game-Changer for Efficiency: WEMAS Embraces an Off-the-Shelf Solution After Eye-Opening Demonstration from OnRobot
WEMAS immediately realized that an Off-the-Shelf palletizing solution powered by D:PLOY was an answer to their problem. “We were immediately impressed and quickly recognized that D:PLOY technology was different to what we had seen before. The palletizing solution was extremely easy to use, which was very important to us”, says i.A. Julian Döring, Head of Materials Management at WEMAS.
WEMAS actively seeks innovative technologies at trade fairs to enhance their processes. During the FMB trade fair in Germany they met with OnRobot’s Dutch partner, Just Automate, who demonstrated the groundbreaking capabilities of their off-the-shelf palletizer branded as MoveComponents and powered by D:PLOY. Captivated by its simplicity and efficiency, WEMAS knew this was the solution they had been looking for. For their project, they selected a configuration featuring an OnRobot VGP20 gripper on a Jaka robot to streamline their operations. "There are plenty of options in the market that claim to offer easy palletizing solutions, but once you see a demo, it often becomes clear they don't live up to the promise," says Julian. "With the MoveComponents solution powered by D:PLOY, it was a completely different experience. What was demonstrated to us is exactly what we got—a smooth, same-day installation that delivered on our standars and expectations."
A Standard Solution for Rapidly Transforming Manual Labor into Efficiency
For Pieter Treffers, CEO at Just Automate, demonstrating the user-friendliness of D:PLOY was effortless.
“It was a perfect match between WEMAS and the D:PLOY-powered solution we suggested, and they have been able to transform a time-consuming and labour-intensive manual process into a consistent, reliable system that has significantly accelerated their processes”, Pieter Treffers comments.
Thanks to OnRobot’s same-day deployment model, the integration process has been efficient and minimally disruptive, with the solution quickly installed and operational. As a result, the organization has been able to reduce the amount of time containers spend on-site, directly cutting down the substantial hourly costs associated with container storage. Furthermore, by eliminating the need to coordinate operators for this task, WEMAS has not only improved labour efficiency but also allowed personnel to focus on other essential activities, enhancing overall productivity.
“As a German manufacturer, we of course do our utmost to deliver on the highest possible level since what we do has a great impact on road and construction site safety”, i.A. Julian Döring comments. “We have grown consistently over the years, and more and more containers loaded with heavy battery boxes have arrived at our factory. It is a real relief that our D:PLOY-powerd Off-the-Shelf solution has been able to eliminate the strenuous manual unloading of the containers. At the same time, we’ve gained significantly improved efficiency with minimal production disruption, which is more than we could have hoped for”, says i.A. Julian Döring.
Improving ergonomics
In the past, one container operator could unload an entire container in 16 hours but in order to lessen the physical aspect associated with unloading the containers, WEMAS typically allocated two employees at the same time to the task.
“Even with two operators, ergonomics weren’t perfect when handling the many heavy boxes. Now, thanks to the complete solution implemented, only one operator is required. We can also very easily do changeovers if the box sizes vary, since we don’t have to do any programming. That is how simple the solution is to use”, Julian Döring comments.
Achieving €30,000 Annual Savings thanks to complete solution.
All over the world, manufacturers like WEMAS need to optimize production, inventory, and equipment utilization to better meet customer demands and improve profitability, especially for tasks previously considered too complex and expensive to automate. This is where complete off-the-shelf solutions powered by D:PLOY come into play. They are affordable, scalable, and ideal for high-mix production tasks where finding sufficient staffing can be challenging. All D:PLOY-powered solutions offer same-day installation, quick changeovers for new box sizes, and full control of operations.
A standout feature of the solutions powered by D:PLOY is the simplicity as no advanced programming skills are needed. It is an off-the shelf complete solution with full price transparency, and it offers straightforward in-house redeployment after an initial setup by one of OnRobot’s regional partners. This is part of the reason why WEMAS found it especially appealing.
“Because the solution has helped us unload and subsequently return the containers much faster, we have been able to minimize storage fees, improve our operational efficiency, and achieve a significant overall cost reduction”, Julian Döring adds. “Basically, all we had to do was to deliver electricity and the internet connection to achieve a yearly 30,000 € cost-saving. Even for a highly efficient German company, this is quite an achievement”, he says.
Significant new market approach
OnRobot has carved out a significant new market approach to collaborative automation for high-mix applications that solves many ongoing labor challenges in ways previously unavailable. Manufacturers like WEMAS can now buy standard, Off-the-Shelf complete applications (such as the MoveComponents palletizer) from trusted regional partners that are flexible, affordable, and can be installed in less than a day. This is exactly what WEMAS needed.
“In a company like ours, we’re aiming for full control of our operations, high productivity, quick changeovers if box-sizes shift – and the shortest possible payback time. This is why I believe we simply couldn’t have chosen a better robotics technology than the one powered by D:PLOY”, Julian Döring ends.
About WEMAS Absperrtechnik GmbH
WEMAS was originally founded in 1971 as a trading company for tool technology and machines. But already in 1978, the S in the name got a new meaning: road safety technology. At that time, WEMAS was one of the pioneers who developed and produced products for the protection of workplaces and road construction sites and distributed them throughout Germany. The pioneering spirit was followed by many product innovations and the transformation of the portfolio from products manufactured mainly in sheet metal to now include robust, easy-to-handle plastic products. Today WEMAS acts as a full-range supplier and has all necessary legal approvals and certificates. It is the products, production, processes and of course the people that have made WEMAS the market leader it is today - by a clear margin. Continue reading on www.wemas.de/en
About OnRobot
OnRobot A/S was founded in 2018 with the mission of breaking down automation barriers and bringing the benefits of automation to manufacturers of all sizes. Headquartered in Odense, Denmark, with offices spread across the globe, OnRobot is the world’s leading provider of the broadest range of tools and application solutions for collaborative applications. All offerings are based on the same ‘One System, Zero Complexity’ philosophy, delivering a unified interfacing experience. OnRobot products and solutions are provided through more than 700 distribution and system integration partners and used in many different industries, making it easier and faster to automate tasks such as material handling, machine tending, assembly, and surface finishing. Please visit www.onrobot.com for more information.
