Achieving full automation of testing and palletizing at Wasiak

Company overview

Wasiak is a Germany-based leader in the automotive sector, specialising in the manufacture of advanced cooling plates for battery systems. As demand for electric vehicles and energy storage solutions continues to grow, Wasiak has prioritised innovation and efficiency in its production processes to maintain a competitive edge.

Executive summary

The implementation of the fully automated line has transformed Wasiak’s manufacturing capabilities. The company has realised significant benefits, including:

• Increased production capacity to meet market demand.
• Consistent, high-quality output, with reduced risk of human error.
• Enhanced traceability and process control through MES integration.
• Optimised labour utilisation, allowing operators to focus on critical support tasks.

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Project objectives

To meet increasing market demands and ensure the highest quality standards, Wasiak set out to transform its manufacturing line with the following key objectives:

• Achieve a cycle time of 6 seconds per unit.
• Integrate sequential product testing with palletising.
• Implement full automation, seamlessly connected to the MES (manufacturing execution system).

The challenge

Wasiak’s existing production line required significant manual intervention, which limited throughput and introduced variability in product quality. The company needed a solution that would not only accelerate production but also guarantee consistent quality and traceability – all while reducing reliance on manual labour.

The solution

Wasiak partnered with leading automation experts to design and implement a state-of-the-art, fully automated production line. The new system was engineered to:

• Automate the entire production process – from profilometric inspection and electrical testing to labelling and palletising.
• Integrate all process steps with the MES system, ensuring real-time data collection, traceability, and process control.
• Reduce the operator’s role to only essential tasks: supplying raw sheets, providing containers and spacers, and collecting finished pallets.

Key achievements

6-second cycle time

The new line consistently achieves a cycle time of just 6 seconds per cooling plate, dramatically increasing throughput and enabling Wasiak to meet growing customer demand.

Automated quality assurance

Profilometric inspection and electrical testing are now fully automated and integrated into the production flow, ensuring every product meets strict quality standards before labelling and palletising.

Seamless MES integration

The automated line communicates directly with the MES system, providing real-time production data, traceability, and process optimisation capabilities.

Operator efficiency

With automation handling the most labour-intensive tasks, operators are now focused on value-added activities, such as material supply and finished goods management, further improving overall efficiency.