The philosophy behind the MicroFactory is to break down complex production systems into dedicated processes per module.
On each module a specific process can be replicated to meet our customers’ specific requirements.
Think in processes, not products.
Not sure where your product portfolio is heading? No problem, our automation platform is process oriented, not product oriented.
Different products have similar manufacturing processes in common. Use one MicroFactory process module for various products and save money.
Automate step-by-step.
Not ready to invest in an entire production line? Start with one process module for a specific manufacturing process.
Gradually add automation to your production when needed.
Stay human – sometimes.
Don’t want to hand over certain production processes from your employees?
Easily integrate manual workstations into a MicroFactory production line at any time. If required, our individual modules are also 100% collaborative.
Reconfigurable by default.
Do you want to be able to adapt your production processes in the future?
Thanks to its modular architecture, the MicroFactory can be reconfigured at any time. Replace individual process modules easily with new modules to meet your new production requirements.
Just plug in the new module and you are ready to go!
Service without downtime.
Does your entire production grind to a halt when individual processes fail? It doesn't have to be that way!
MicroFactory modules can be easily removed from the line for service and replaced with a manual workstation during the service period, ensuring very high system availability.
Batch size "1"
Designed to meet the challenges of high mix/low volume production, the MicroFactory can produce very small batch sizes, starting at one piece.
Instant one-button set up
Constant setup reduces your system availability? Our MicroFactory modules set up completely autonomously and instantly at the push of a button. Produce seamlessly and save time!
Spare parts on demand
Save space and money! No need to stock spare parts. Our standardized module components will be delivered to you within 24 hours.
Clients
Real businesses, real results.
The result is very satisfying! We were able to save about 75% of the costs. Without this measure, we would have had to relocate or even lost the products.
Dirk Kinzel
Engeser GmbH
At Roche, we were looking for a modular, flexible solution for assembling different devices and found this solution in ESSERT´s automation platform. The collaboration with ESSERT was characterized by a high level of innovation and the willingness to adapt to the requirements of the pharmaceutical industry.
Philip Schneider
Drug Product Manufacturing Network Technology Lead at Roche
ESSERT’s standardized robotics platform guarantees fast availability and makes it more cost-effective than classic special solutions.
Martin Rasch
HUMMEL AG
The robot workstation impresses with its flexibility, scalability and integration of state-of-the-art camera technologies.
Arno Schroff
Department manager for plant and site development at Vetter
Discover our scalable MicroFactory solution for syringe and PEN assembly in variable batch sizes as well as high format variance without setup operations.
Do you need short delivery times and fast commissioning?
All modules are tested and fully commissioned with our mobile commissioning station. When the modules are delivered to your site, all you have to do is plug in and start producing.
No on-site assembly. Very short commissioning times due to a high level of standardization.
Full control at all times
The Process Control Center (PCC) is the command center of your MicroFactory and bundles all relevant data in one central location.
Data visualization: Extensive data and process visualisation as well as the possibility to create your own dashboards.
Central recipe management: Manage all recipes via a central recipe database and quickly activate & prepare products.
Coordination: The Process Control Center coordinates the overall production flow and ensures 100% good parts.
MES connection: Central interface to your production planning systems.
The beauty of production data.
Want to gain visibility into your production data?
With the performance dashboard of the Process Control Center (PCC), you can monitor all process modules in real time and visualize relevant data in one central location.
You have full visibility into your production data at all times.
Camera assisted Line Clearance.
Need to make sure the line is clear of parts before and after producing a batch? Well, more eye pairs are better than one.
Our modules use intelligent camera technology to automatically perform a line clearance check after each batch production and notify you of a positive result.
How does it work? - The magic behind our automation platform.
It all starts with the BASE for each process module. Highly standardized and yet able to fully support all your specific requirements for your individual process.
Everything you need to successfully automate your process in one place, with the option of combining robots, safety technology, camera technology, material supply, etc. according to your needs on a modular basis.
Examples for process modules
3D Bin Picking Module
Thanks to specially developed algorithms, transparent and reflective objects such as glass or plastic bodies can also be reliably detected in addition to plastics, metals and sheet metal.
Flexible Feeding Module
Components can be easily and flexibly separated by vibration and thus gripped by the robot; in addition, a choice can be made for illumination between transmitted light, incident light or side light.
Tray Stacker Module
Tray Stacker for maximum autonomy in minimum installation space. The tray Stacker is fully integrative and parameterisable via the user tablet. Maximum tray dimensions: 600mm x 400mm
Drawers Module
The drawer system is ideal for all products that cannot be organized in trays or boxes. The inlays of the drawers can be custom-made and product-specific.
Labelling Module
Integration of inline labellers including optional label inspection. The labels can be applied flat or to round bodies. Flexible interfaces for print data exchange are also available.
Tray Module
The Tray Module provides space for 600mm x 400mm trays and allows components to be placed or picked by a robot.
Laser Module
Engraving of components or assemblies using CO2, UV or fiber lasers.
Assembly Modules
Various assembly modules such as O-ring or syringe assembly stations, individually designed, manufactured and commissioned according to requirements.
Smart conveyor technology.
Transform your production line with our cutting-edge, FDA-certified smart conveyor system.
It connects multiple process modules to form a MicroFactory, featuring a flexible workpiece carrier for numerous products and an easy plug-and-produce connection for quick integration.
Perfect for industries demanding high hygiene standards and efficiency.
GMP and GAMP Services.
We adhere to GMP and GAMP guidelines and provide comprehensive documentation, validation, and qualification.
Our services include traceability matrix, risk analysis, Failure Modes and Effects Analysis (FMEA), design documentation, qualification, CE conformity assessment, audit trails, change control, training documentation, internal audits, Standard Operating Procedures (SOPs), deviation management, and data integrity to ensure full compliance and customer satisfaction.
What makes the architecture of the ESSERT MicroFactory special?
Our ESSERT MicroFactory is the perfect solution for your production needs. Its modular design allows us to combine process modules in any way you require, ensuring we can meet your individual requirements perfectly.
The MicroFactory is highly flexible and scalable, making it the ideal choice for high mix/low volume production. It increases your efficiency and opens up new possibilities for you.
The MicroFactory philosophy is based on the division of complex production systems into dedicated processes per module.
Can the MicroFactory modules be operated separately?
Absolutely! Individually operated process modules are also possible, thanks to their own PLC (Programmable Logic Controller). They can either take over a constant process section or complete production sequences.
To further increase speed and versatility in production workflows, several process modules can be combined to form an ESSERT MicroFactory.
How can the ESSERT MicroFactory make production more flexible?
The possibilities are endless with MicroFactory! You can use it to manufacture a wide range of products with similar manufacturing processes. Automate your production step by step and add more modules as needed.
Integrate manual workstations into a MicroFactory production network at any time. Our modules are also collaborative, so you can work together seamlessly.
Can skilled workers be involved in the process chain? (manual workstations)?
Absolutely! You can integrate manual workstations into a MicroFactory production network at any time.
Our systems meet the highest safety standards for human-robot collaboration. This means you can still carry out specific work steps, such as inspection or packaging, manually.
Can existing systems be added to the automation process?
Existing systems can be integrated into automated processes. Our standardised solutions for process automation offer numerous interfaces, allowing our process modules to be connected to existing customer systems and become part of the overall automation.
Is it possible to retrofit and switch to other products?
Absolutely! The production network of an ESSERT MicroFactory can be easily supplemented by additional process modules at a later date, or by replacing existing process modules with others.
How long does it take to switch to new products?
Our MicroFactory modules are ready to go as soon as you need them! They set up themselves automatically and immediately at the push of a button, so you can produce without interruption and save time!
Do I need to change the format for new products?
Absolutely not! Our systems are designed to be flexible, so they don’t require the extensive retooling of rigid mechanical components when changing products. Instead, they rely on flexible component feeders, which are software-based and fully automated during a set-up process.
What analysis options are available for my production with the MF?
The Process Control Center (PCC) provides a clear overview of all relevant process data and parameters. It also offers extensive analysis tools, ensuring that automated processes are highly transparent and traceable.
Can the system also be used in a cleanroom?
The GMP-compliant version of the ESSERT MicroFactory can also be used in cleanrooms up to ISO class 5. Our hygienic design based on stainless steel is optimised for the pharmaceutical sector.
High Mix / Low Volume (HMLV) manufacturing meets the growing customization needs in industries like life sciences. ESSERT Robotics offers solutions for diverse industries, especially in low volume medical device assembly.
High Mix / Low Volume is an increasingly prominent production approach in the pharmaceutical sector. This correlates with the rise of advanced therapies that are custom-made for a small group of individuals – or even one single patient.
This article explains the two different production methods, High Mix / Low Volume (HMLV) & Low Mix / High Volume (LMHV) and compares the advantages and disadvantages of both strategies.
With the manufacturing world moving towards more personalized products and unique market segments, LVM is gaining significant traction. Industries ranging from electronics to life sciences have decided for LVM to successfully supply their unique clientele.
