Teklas Bartın Facility – Industry 4.0 and Smart Factory Transformation
Teklas has implemented comprehensive automation investments in its facilities to increase efficiency, minimize human errors, and ensure production continuity in both manufacturing and intralogistics processes. As part of this transformation, automated storage systems, robotic marking cells, automated vulcanized product storage systems, and AGV (Autonomous Guided Vehicle) solutions were integrated into operations.
Challenges
Before automation, the facility faced several operational challenges:
- Products were manually placed on racks, leading to incorrect location assignments.
- Human-related inventory and counting errors frequently occurred.
- Missing products resulted in unnecessary re-production activities.
- Storing vulcanized products on the floor reduced space utilization and caused product losses.
- Material transfers between production areas were performed manually.
- Marking processes involved quality and traceability risks.
Solution
To eliminate these challenges, Teklas implemented several automation systems:
Automated Storage and Retrieval System (ASRS)
Cases coming from production are barcode-labeled and transferred to the automated storage system. The system automatically places products in appropriate locations and delivers them to operators according to the FIFO principle whenever needed.
System features:
- 6.500 case storage capacity
- Management of 5.500 foldable cases
- Fully automated storage and retrieval
- FIFO inventory management
- 24/7 operational capability
Vulcanized Product Storage
A robotic storage system is used for storing and supplying vulcanized products to production. Products identified through barcodes are automatically stored according to the FIFO principle and delivered based on production demands.
System features:
- 150-meter-long storage line
- Capacity for 2.400 vulcanized cases
- Fully automated inventory management
- Elimination of product losses
AGV (Autonomous Guided Vehicle) System
Two mobile robots operating within the facility fully automate material transfers between production cells. Through barcode integration, the robots transport the correct product to the correct location, optimizing internal logistics processes.
Results
As a result of the automation investments:
- Human-related inventory errors were significantly reduced.
- Product losses were eliminated.
- FIFO inventory management was fully ensured.
- Product traceability and availability improved.
- Manual material handling requirements decreased.
- Marking quality and process reliability increased.
- Production continuity and operational efficiency improved.
- Storage capacity was significantly increased.
Customer Benefits
- Higher production efficiency
- Lower operational costs
- Enhanced traceability
- Maximum utilization of storage capacity
- Error-free product flow
- 24/7 uninterrupted operations
- Sustainable and scalable production infrastructure
Future-Ready Manufacturing
Through automated storage systems, robotic applications, and AGV technologies, Teklas has successfully digitalized its production processes and implemented its Industry 4.0 vision. As a result, its facilities have become more efficient, more traceable, and fully prepared for the future demands of manufacturing.
Teklas Bulgaria Facility – Automated Warehouse and Material Flow Optimization
Teklas Bulgaria has invested in advanced warehouse automation technologies to support growing production volumes, improve material flow efficiency, and maximize storage capacity. The project integrates pallet and container storage systems, automated transport technologies, and seamless production line connectivity to create a fully automated intralogistics environment.
Challenges
As production volumes increased, Teklas Bulgaria required a more efficient and scalable intralogistics infrastructure to support continuous manufacturing operations.
- Limited warehouse capacity for growing production demands.
- Manual pallet handling processes reducing operational efficiency.
- Need for uninterrupted material flow between warehouse and production.
- Requirement for accurate inventory tracking and traceability.
- Optimization of warehouse space utilization.
- Reduction of forklift traffic and manual transportation activities.
Solution
Teklas Bulgaria implemented a fully automated warehouse and material handling solution designed to connect storage operations directly with production processes.
Automated Storage and Material Handling System
The solution combines automated pallet storage, conveyor transport systems, RGV technology, and a Miniload ASRS to ensure uninterrupted material flow between warehouse operations and production lines.
System Features
- Inbound receiving and inspection area
- RGV-based pallet transfer system
- Single Deep Pallet Crane ASRS
- 2,500 pallet storage locations
- Integration with 5 fully automated production lines
- Automated pallet conveying system
- Real-time warehouse management and tracking
Miniload ASRS System
In addition to pallet storage automation, the facility utilizes a Miniload ASRS designed for high-density storage and rapid retrieval of containers and production materials.
System features:
- 3.000 storage locations
- Automated storage and retrieval operations
- High-speed order fulfillment capability
- Improved inventory accuracy
- Seamless integration with production supply processes
Integrated Production Connectivity
The automated warehouse infrastructure is directly connected to five fully automated production lines through pallet conveying and RGV systems. This integration enables continuous material flow while minimizing manual intervention throughout the facility.
Results
As a result of the automation investment:
- Increased storage density and warehouse capacity.
- Fully automated pallet and container handling operations.
- Seamless connection between warehouse and production processes.
- Reduced forklift traffic and manual transportation requirements.
- Improved inventory accuracy and product traceability.
- Faster material delivery to production lines.
- Enhanced operational efficiency and productivity.
- Scalable infrastructure supporting future growth.
Customer Benefits
- Optimized warehouse utilization.
- Higher throughput capacity.
- Reduced operational costs.
- Improved process reliability.
- Real-time inventory visibility.
- Enhanced workplace safety.
- Future-ready automated logistics infrastructure.
Future-Ready Manufacturing
By integrating a Single Deep Pallet ASRS, Miniload technology, RGV systems, automated conveying solutions, and production line connectivity, Teklas Bulgaria has established a highly efficient logistics ecosystem capable of supporting continuous manufacturing operations and future expansion plans.