Custom Automation Cart for Internal Assembly | OTC Industrial Technologies

Overview

A manufacturing customer needed to transition from outsourced development to internal development of their assembly and automated testing equipment. While they had deep process knowledge, they lacked internal resources for automation design, software programming, and physical system builds. They also faced spatial constraints, with no designated fabrication area and limited access through small lab doors.

Recognizing the challenge, the customer partnered with OTC Industrial Technologies to co-develop a modular automation cart that would enable streamlined internal assembly and testing, without overextending their staff or physical footprint.

• Customer: Electronics Manufacturer
• Relationship with OTC: 10 Years

Challenges

The customer was eager to bring critical assembly and testing capabilities in-house, but several hurdles stood in the way:

• Lack of internal automation resources: They had no available technicians or programmers to design and build the system.
• No dedicated fabrication space: Their facility did not have an appropriate build area for assembly work.
• Access limitations: Equipment needed to pass through small lab doorways, making conventional carts and systems impractical.

These constraints demanded a flexible, scalable solution that minimized disruption and maximized adaptability.

Solution

OTC engineers collaborated closely with the customer to design and fabricate a custom automation cart built on Bosch Rexroth automation  and conveyor components. The cart was engineered to meet tight spatial constraints and included:

• A compact, modular design that fits through narrow lab doorways
• An integrated remote access system allowing OTC to perform software updates and troubleshoot controls off-site
• Plug-and-play architecture for future modifications and expansions by the customer

This turnkey solution empowered the customer to deploy advanced internal testing equipment without investing in new space or staff.

Results

The OTC team delivered measurable advantages:

• Streamlined deployment: The customer launched new production and test systems without hiring new staff or diverting internal resources.
• Cost savings: OTC’s remote access capability eliminated the need for on-site service calls, saving on travel, lodging, and downtime.
• Long-term flexibility: The modular system allowed the customer to adapt and expand their workstation layout independently as their needs evolved.

By combining engineering expertise with remote support and a scalable system design, OTC enabled the customer to bring automation in-house quickly, cost-effectively, and on their terms.

If you are in need of automation system design services or industrial automation solutions, contact the experts at OTC to add value to your operations.