Country: Slovenia
Focus area:Green, Digital
Thematic area:
Digitalization and Connectivity, Automation and Robotics, Data Analytics and Artificial Intelligence, Additive Manufacturing and 3D Printing, Renewable energy technologies, Waste reduction and Recycling Technology , Energy-Efficient Technologies
TRL phase: TRL 9 - actual system launched on the market (System launched)
Addressed business processes: INBOUND LOGISTICS process , MANUFACTURING OPERATIONS process , CUSTOMER CUSTOMER SERVICE process , PROCUREMENT process , TECHNOLOGY DEVELOPMENT process , OUTBOUND LOGISTICS process
Solution overview
The ETRA Modular Intelligent Robotic Cell is a customised turnkey solution for automating repetitive, physically demanding, hazardous or quality-critical manufacturing operations. Depending on the application, it can perform material handling, assembly, machine tending, welding, inspection, packaging, palletising and other production tasks.
The solution combines industrial or collaborative robots, customised tooling, machine vision, sensors, safety systems, PLC/HMI/SCADA control, production-data collection and connectivity with existing equipment and information systems. Its main objectives are to increase productivity and process repeatability, improve quality and traceability, reduce manual work and production errors, and create safer and more energy-efficient manufacturing processes.
The solution is intended for manufacturing companies of all sizes seeking to automate a new process, modernise an existing production line or validate an advanced robotic application before full-scale implementation.
Key features
The solution is developed specifically around the customer’s product, production process, available space and performance requirements. Its modular architecture enables the integration of different robot brands, collaborative robots, machine-vision systems, customised grippers, safety equipment and production technologies.
ETRA combines mechanical and electrical engineering, robotics, automation, software development, machine vision, digitalisation and industrial safety within a single multidisciplinary team. This provides the customer with one responsible partner throughout the complete project lifecycle.
Key differentiating features include digital simulation before physical implementation, testing and Factory Acceptance Testing at ETRA’s facilities, flexible product-change configurations, integrated quality control and traceability, real-time production monitoring, remote diagnostics and energy-efficient operating modes. The system can subsequently be expanded or adapted to new products and production requirements.
Integration and adaptability in manufacturing environments
The solution can be implemented as a standalone robotic cell or integrated into an existing machine, production line, warehouse or wider manufacturing system. ETRA first analyses the existing process, equipment, layouts, cycle times, product variants, safety requirements and available communication interfaces.
Mechanical dimensions, tooling, robot type, control architecture, safety concept, user interface, inspection functions and data connectivity are customised for each application. The solution is compatible with commonly used industrial robots, PLC systems, sensors, drives, machine-vision equipment and industrial communication technologies, including PROFINET, OPC UA, Modbus and other project-specific interfaces.
It can also exchange production, quality, traceability and maintenance data with SCADA, MES, ERP and other higher-level systems. Phased implementation and retrofit approaches are available to minimise disruption to existing production.
Implementation support and training for manufacturers
ETRA supports customers throughout the complete implementation process, including process assessment, feasibility analysis, concept development, simulation, mechanical and electrical engineering, robot and PLC programming, assembly, integration, Factory Acceptance Testing, installation, Site Acceptance Testing and production start-up.
Operators, maintenance personnel and engineers receive application-specific training covering system operation, product changes, safety procedures, troubleshooting and basic maintenance. Technical documentation, operating instructions, maintenance guidance and recommended spare-parts lists are provided according to the agreed project scope.
After implementation, ETRA offers remote diagnostics, process optimisation, software modifications, preventive, predictive and corrective maintenance, spare-parts support and contractual 24/7 service. The solution can also be upgraded when the customer introduces new products, processes or digital requirements.
Sustainability, compliance and certifications in the EU
Each robotic solution is engineered and assessed according to the EU legislation applicable at the time it is placed on the market, including relevant requirements for machinery safety, electrical equipment and electromagnetic compatibility. The conformity-assessment scope and CE documentation are defined according to whether ETRA supplies a complete machine, a robotic cell or an integration into an existing production system.
Risk assessment, safety design and validation are performed using applicable standards and recognised engineering practices, including standards related to machinery risk assessment, industrial robot safety, collaborative robot applications, safety-related control systems and electrical equipment of machines.
Performance and safety functions are verified through documented internal testing, Factory Acceptance Testing and Site Acceptance Testing. ETRA operates certified ISO 9001 quality-management and ISO 14001 environmental-management systems and is a Siemens Solution Partner and certified robot integrator. Any additional sector-specific certification or validation is agreed according to the customer’s application and industry.
Example of successful implementation of solution in manufacturing company.
ETRA successfully developed and implemented automated headlight assembly system for automotive company. The solution integrates seven industrial robots operating simultaneously within a 40-second production cycle.
The system combines several demanding manufacturing and quality-control operations: plasma cleaning, precision adhesive application, bonding of the headlight housing and lens, leak testing, electrical testing, machine-vision inspection and laser engraving.
ETRA integrated the mechanical equipment, robotics, process technologies, sensors, safety systems and automated control into a coordinated production system. The project demonstrates ETRA’s capacity to develop and validate complex, multi-robot production cells in which assembly, testing, inspection and product identification are performed within a single automated process.
Case studies or testimonials showcasing the impact of the solution on real-world operations.
ETRA’s modular robotic and automation solutions have been successfully implemented in several hundred applications, in between also in the following manufacturing applications:
• Cup quality control and assembly system: The system combines a vibrator, pusher and automated cup manipulator with camera-based position control, dimensional verification, automatic screw dispensing and fastening, barcode application and inspection, and integration with the customer’s MES. The solution provides automated assembly, quality verification and production traceability within one integrated process.
• Automated plastic insert installation: Plastic inserts are automatically fed onto a conveyor and inspected using machine vision to identify suitable components. Three robots simultaneously install the inserts to meet a 10-second production cycle. Final product quality is verified through an end-of-line machine-vision inspection.
• Flexible die-cutting robotic cell: The robotic cell automatically feeds glued sheets into a die-cutting machine. Machine vision identifies the required die-cut areas within a 1 mm tolerance. Automatic product recognition and machine adjustment enable the system to process 36,200 different product combinations.
These applications demonstrate the flexibility of ETRA’s solution across automotive, household-appliance, battery and specialised manufacturing processes. They also confirm ETRA’s ability to integrate robotics, machine vision, quality control, traceability and production-system connectivity into reliable industrial solutions.
Link to the solution video or pdf technical documentation.
ETRA company and technology overview, development activities and technological solutions:
https://etra.si/en/etra/
Selected robotic, automation, machine-vision and digitalisation references:
https://etra.si/reference/
Additional videos, photographs and technical documentation for individual solutions are available upon request, subject to customer approval and applicable confidentiality requirements.
Expected return on investment (ROI)
The expected return on investment is calculated individually because it depends on the complexity of the process, number of shifts, labour requirements, production volume, cycle time, product mix and existing level of automation.
For technically and economically suitable applications, the targeted payback period is typically approximately two to four years. Returns are generated through increased production capacity, reduced manual work, lower scrap and rework rates, improved quality, shorter cycle times, reduced unplanned downtime, better traceability and improved workplace safety.
Before implementation, ETRA can prepare a techno-economic assessment comparing the initial investment and total cost of ownership with the expected annual operational savings. The final ROI and payback period are therefore based on the customer’s validated production data and are not presented as a guaranteed universal value.
Cost overview: implementation and ongoing expenses
Initial costs depend on the required level of automation and may include process analysis, concept development, simulation, mechanical and electrical engineering, industrial or collaborative robots, customised grippers and tooling, machine-vision equipment, sensors, safety systems, PLC/HMI/SCADA equipment, software development, assembly, Factory Acceptance Testing, installation, commissioning, documentation and operator training.
ETRA prepares a project-specific commercial proposal with a clearly defined technical scope, deliverables, implementation schedule and costs. Where appropriate, implementation can be divided into phases to reduce initial investment and enable future expansion.
Ongoing expenses may include preventive maintenance, periodic safety inspections, calibration, replacement of wear parts, spare parts, software updates, remote support and corrective maintenance. Energy consumption and maintenance requirements are considered during system design. ETRA also offers contractual 24/7 support, predictive and corrective maintenance, with service costs defined according to the required response time and scope of coverage.
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