Karakuri – Automate production without electricity ⚙️

Cem Dogan
1 day ago
2 min read

Karakuri (Japanese for "mechanism") means purely mechanical automation , completely without electricity, sensors or compressed air. Instead of high-tech, only muscle power, gravity and intelligent mechanics are used - ideal for quickly and easily transporting small cargo carriers (SLCs) from point A to point B.

Why Karakuri (Low Cost Automation, LCA)?

Ready to use in an instant : Often ready within days, whereas traditional dedicated machines take months or even years.
Cost savings : No expensive drive, less materials, no energy costs – a NORDAKADEMIE study shows up to 40% cost savings compared to conventional automation.
Easy maintenance and understandable : On-site mechanics can repair immediately because they developed the mechanics themselves.
Sustainable and modular : Reduces CO₂ footprint, can be reused, adaptable – ideal for changing production requirements.

Requirements for projects in Karakuri

Lean thinking throughout the company. Kaizen (continuous improvement) is crucial: employees must recognize waste and actively develop mechanical solutions.
Foster employee creativity. Mechanics and technicians are the driving forces – with ideas, freedom, training and their own prototyping area.
Iterative prototyping instead of CAD planning. Rapidly build, test, optimize, document – then comes the final drawing.
Expert support. External consultants from Karakuri can provide expertise and facilitate workshops.

Where does Karakuri work?

Intralogistics : transport bridges, automatic racks, box dumpers, rotary systems – usually for loads between 2 kg and 12 kg.
Special solutions : Mechanical syringes for material feeding, tilting, rotating, lifting – especially fast to implement.

Hybrid Solutions: When Mechanics Alone Isn't Enough

For heavy loads, Karakuri can take over the mechanical control logic, while traditional drives complement the system. A Toyota project in the Czech Republic impressively demonstrates this: a 6 × 6 × 5 m bridge carries air conditioning units across a passage – completely mechanically coordinated, with minimal technology.

Advantages at a glance

Advantage	Description
speed	The solution is often feasible in days instead of months
Price	Low development costs, no energy costs
maintenance	How to self-repair, soon self-repair
sustainability	Less CO₂, less material
flexibility	Modular system – easily adaptable

Conclusion

Karakuri is a symbol of simple, fast and cost-effective automation with intelligent mechanics instead of expensive electronics. It requires lean thinking, enthusiastic employees and iterative processes – and delivers impressive efficiency and environmental benefits. With a hands-on approach, a prototyping area and external support, LCA in Karakuri can be effectively implemented within a company.

🔧 Do you dare to start?

Offer training and seminars on Karakuri
Strengthen lean teams , give mechanics room for creativity
Small pilots start – for example, a removable frame or a firing mechanism

If you are ready to achieve great things with simple means, Karakuri could be the next step towards the innovative and sustainable manufacturing of tomorrow.

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