Karakuri – Mechanical automation for smarter production

Karakuri is a Japanese term that describes a type of mechanical automation where gravity and simple mechanical principles replace motors, sensors, and advanced controls. It is a central part of lean production and low-cost automation, where the goal is to optimize material flows and ergonomics with minimal resources.

What is Karakuri?

Karakuri is based on mechanical solutions for transporting, lifting or redistributing materials in production without relying on electricity. The concept originates from traditional Japanese vending machines from the Edo period, but has been developed into an industrial solution that fits perfectly into the lean philosophy.

By using mechanical links, springs, levers and roller tracks, Karakuri solutions can automate tasks in a simple and cost-effective way. The goal is to reduce manual handling, improve ergonomics while avoiding expensive and complex systems.

The benefits of Karakuri

Karakuri offers several advantages over traditional automation:

• Low-cost automation – No motors, sensors or PLC-controlled systems are required, which makes the investment lower.
• Energy independence – Because the solutions work with gravity and mechanical principles, they do not require an external energy source.
• Reduced maintenance – Karakuri systems consist of simple mechanical parts that require minimal maintenance compared to electrical systems.
• Flexibility and adaptability – A Karakuri solution can be easily modified or moved to suit new needs.
• Improved ergonomics – Reduces the need for heavy lifting and repetitive movements, creating a better working environment.

How to implement Karakuri in production?

Implementing Karakuri requires an understanding of both lean principles and basic mechanics. Here is a step-by-step process:

1. Identify needs and problem areas
   • Which stages of production require unnecessary manual handling?
   • Are there ergonomic problems related to material flow?
2. Design a solution
   • Use mechanical principles such as levers, springs or inclined planes.
   • Ensure that the solution is simple, robust, and easy to maintain.
3. Build a prototype
   • Test the solution on a small scale and evaluate its effectiveness.
   • Adjust and improve based on operator feedback.
4. Implement in production
   • Create standardized work procedures around the new solution.
   • Ensure that employees are trained in how the system works.
5. Continuous improvement (Kaizen)
   • Monitor performance and adjust as needed.
   • Look for new opportunities to use Karakuri for further efficiency improvements.

Examples of Karakuri solutions

Shooter solutions

A shooter is used to push a box or load carrier from a flow rack to a pickup point. By utilizing an inclined surface or a spring mechanism, the operator can easily retrieve material without having to reach or lift heavy objects.

Lifting mechanisms without motors

By using counterweights or springs, Karakuri solutions can create lifts or lifting systems that do not require electricity. This is especially useful in workstations where different height levels are frequently used.

Flowrack for material transport

Instead of motorized conveyor belts, Karakuri tracks can use gravity and mechanical linkages to move materials between stations, reducing energy consumption and maintenance requirements.

Karakuri in practice

Several large industrial companies have implemented Karakuri solutions to optimize their production flows. Working with Karakuri creates a more flexible and sustainable production that is less dependent on complex and expensive automation.

Want to try Karakuri yourself?

For those who want to explore the Karakuri concept, we offer mini Karakuri kit which can be used for inspiration and education. By experimenting with different mechanical solutions, you will gain a better understanding of how Karakuri can be applied in real production environments.

Discover more in our new webshop!

We have recently launched our new webshop , where you can find both Karakuri components and other solutions for lean production. In addition, we are happy to help you start your own lean shop .

Would you like to know more about how Karakuri can help your production? Contact us and we will tell you more!