Automated material handling

KUKA's mobile robotics solutions turn your material handling into a smart link between warehouse and production – fully automated, safe and flexibly scalable. Our solutions and automated systems intelligently connect stations, relieve employees and increase the efficiency in intralogistic automation.

Why intelligent material handling is essential

Internal material handling is increasingly becoming the focus of modern manufacturing, shipping and intralogistics automation strategies. Businesses face the challenge of using limited space efficiently while managing the increasing complexity in materials, tasks and logistics. Conventional manual transport methods, such as manual handling with forklifts or non-integrated vehicles, quickly reach their limits: They cause collisions, make transparency difficult and hinder consistent planning and control of material flow. To overcome these issues, smart, automated material handling systems are needed that can be seamlessly integrated into existing workflows.

How can material flows be flexibly automated with KUKA?

KUKA offers autonomous mobile robotics and intelligent software solutions that automate internal transport, optimize material handling solutions, and enable precise, data-driven management of your logistics processes. This reduces manual tasks, increases operational safety and ensures scalable, sustainable automation – flexibly adaptable to your requirements, components, and functions. Material flow thus becomes a strategic success factor for maximum efficiency, agility, and competitiveness:

Flexible system
- Quick adaptation to new layouts, products or tasks
- Integration with stationary robots and cobots
- Suitable for small batch sizes and high variety
- Flexible interfaces for project-specific superstructures and sensor technology
Safety in mixed operation
- 360° laser scanner with dynamic safety zones
- 3D obstacle detection and avoidance
- Safety architecture according to SIL2/PLd, etc.
- Optional safety bumper for risk minimisation
Digital system integration
- Open interfaces (OPC UA, REST API) for connecting external systems (MES, WMS, etc.) and peripherals
- Fleet management with KUKA.AMR Fleet for optimal route planning
- Simulation and planning via iiQWorks Engineering Suite
Sustainable scalability
- Broad AMR portfolio for various areas and applications
- Modularly expandable fleet with software and sensor technology
- Compatible with AI-supported functions
- Global service throughout the entire lifecycle

Ready to optimize your material handling?

Take the next step towards achieving your goals with tailor-made, automated transport solutions for materials and goods – perfectly matched to your production and supply chain.

Get advice now Order material handling systems via my.kuka

Future-proof automation for sustainable optimisation of material flow

Our material handling solutions are based on an intelligent, scalable infrastructure. From autonomous mobile robots (AMRs) to networked control software, we enable continuous, data-based, reliable design and optimisation of material flow, including material flow analysis.

Intelligent fleet management

Software for controlling, monitoring and analysing your autonomous mobile robot fleet for optimal material flow in production and logistics.

Transport robots for topload applications

Mobile robot platforms with and without superstructures for specific transport tasks.

Autonomous mobile robot in a dynamic production environment with humans

Mobile manipulators

Mobile robot systems optimize material flow through active handling. They transport goods, pick them up precisely, position them and transfer them.

The autonomous mobile robot makes human-machine collaboration possible and improves your company's intralogistics operations

Typical applications within intralogistics

Line supply / Just-in Sequence

Precise material handling in cycle times and in the correct order – without buffer losses. Ensures stable processes, reduced storage space and maximum cycle accuracy.

Assembly supply & parts logistics

Reliable material handling systems at workstations on multiple levels – safe, synchronised and traceable. Flexible adaptation to product changes and cycle times.

Machine tending

Automated feeding and removal of workpieces or tools – e.g. during milling – for precise operations, high process reliability and smooth machine integration.

Material handling in clean rooms

Clean room-compatible transport of sensitive components such as wafers and circuit boards – ideal for electronics manufacturing with fewer manual interventions.

Return & empty container logistics

Closed material flow cycles through automated return of empty load carriers for clear structures, greater order and efficiency.

Buffer sections and intermediate storage

Flexible intermediate storage thanks to modular and scalable systems for decoupling processes – space-saving, modular and adaptable. Compensates for cycle time differences.

Our customers rely on automated material flows and intelligent transport

Whether in series production in the automotive industry, precise parts logistics in mechanical engineering or hygienically sensitive packaging in food processing – automated material handling and intralogistics play an indispensable key role in businesses. Our smart automation solutions enable the intelligent and flexible design of internal operations, empowering our customers to master complex challenges and achieve measurable success.

Frequently asked questions (FAQs) about automated material handling

How can a KUKA material handling system be integrated into existing production facilities?

KUKA offers open interfaces such as OPC UA and other industry standards to easily integrate our material handling equipment into existing facilities, ERP systems or MES platforms. Our experts will support you with customised integration.

How flexible are KUKA systems when it comes to changes in layout or product mix?

KUKA systems are specially designed for dynamic production environments. The mobile robot platforms can be easily reconfigured using intuitive software solutions, such as the no-code fleet manager, without any programming knowledge. Robot cells with flexible grippers and smart control concepts are also engineered to adapt quickly to new requirements and short product life cycles.

How do I find the right solution for my material handling needs?

In addition to personal advice from our experts, the interactive KUKA Robot Guide offers you a decisive advantage: It helps you find the right material handling solutions for your tasks quickly, easily and effectively – tailored to your operations, materials and areas of application.

Find the right solution now with the KUKA Robot Guide

Interactive user interface of the KUKA Robot Guide for selecting the ideal material handling equipment for optimized transport

What are the maintenance and service requirements for KUKA systems?

The systems are engineered for 24/7 industrial operation. KUKA offers predictive maintenance, remote diagnosis, training and service contracts with fast response times. The mobile platforms also perform self-diagnosis and report maintenance requirements at an early stage.

Further information about our tailor-made service

What solutions does KUKA offer to support machine tending with mobile robots?

KUKA combines transport robots with stationary robots to create flexible system solutions for machine tending. The AMRs autonomously transport raw materials or workpieces to the machine, where a robot precisely inserts them. This results in continuous, automated material handling: no manual intervention, high process reliability and optimal machine utilisation.

Further information on automated machine feeding

Cobot solution for the automation of machine tending

How intelligent and safe are KUKA AMRs?

Our mobile robot platforms feature modern sensor technology, SLAM navigation and fleet management. They recognise obstacles, plan routes dynamically and can be integrated into existing IT and warehouse management systems.

How important is internal material flow in companies?

Material handling automation refers to all operations and processes in which goods, materials, auxiliary materials or merchandise are moved within a company or between different locations. Material flow thus encompasses both transport between production steps and distribution in the warehouse and shipping.
Efficient organisation of internal transport is crucial to running production processes smoothly, avoiding bottlenecks and reducing costs. Companies benefit from a smooth material flow through shorter throughput times, lower inventories and higher added value.

Automated material handling

Why intelligent material handling is essential

How can material flows be flexibly automated with KUKA?

Flexible system

Safety in mixed operation

Digital system integration

Sustainable scalability

Ready to optimize your material handling?

Future-proof automation for sustainable optimisation of material flow

Intelligent fleet management

Transport robots for topload applications

Mobile manipulators

Typical applications within intralogistics

Line supply / Just-in Sequence

Assembly supply & parts logistics

Machine tending

Material handling in clean rooms

Return & empty container logistics

Buffer sections and intermediate storage

Our customers rely on automated material flows and intelligent transport

Automation in ceramic production: KUKA robots preserve “Made in Italy” quality

Automated internal material handling with AMRs

Robotic Automation for Utility-Scale Solar Installation

Optimized material flow in production thanks to AMRs

Automated furniture manufacturing with AMR and palletizing robots

Robot-based machine tool automation

Machine loading with cobots

Assembly line for battery pack production

Frequently asked questions (FAQs) about automated material handling

How can a KUKA material handling system be integrated into existing production facilities?

How flexible are KUKA systems when it comes to changes in layout or product mix?

How do I find the right solution for my material handling needs?

What are the maintenance and service requirements for KUKA systems?

What solutions does KUKA offer to support machine tending with mobile robots?

How intelligent and safe are KUKA AMRs?

How important is internal material flow in companies?

Related topics for internal material handling

Autonomous mobile robotics

Machine tending

eBook: Simple Automation with AMR

Webinar: How will AMRs revolutionize the modern production?