March 1, 2023

Bridging Work Cultures: A Graduate’s Unique Perspective on Startups and Corporations

Vitus Henning is our first Jungheinrich International Graduate. As one of the assignments of the programme, he has joined the Project Engineering team at arculus for the research and development of our autonomous mobile robot - the arculee. The initiative gives him a unique opportunity to experience the best of corporate and startup cultures. In this article, Vitus shares valuable insights about the program, his role, and his learnings thus far.

Hi Vitus. Thank you for joining this interview! Please tell us a little about yourself.

Vitus: “I am 25 years old and come from Darmstadt, a city near Frankfurt. After completing my Master's in Robotics, Mechatronics, and Automation at the Karlsruhe Institute of Technology, I joined Jungheinrich as a graduate. One of my assignments is planned with the Project Engineering team at arculus, so I am working at the Munich office for the next few months.”

What is the Jungheinrich International Graduate programme? How does it work?

Vitus: “It is a two-year program. Generally, graduates get an overview of Jungheinrich, learn the organisational structure, and understand the company procedures. It also prioritises specialisation. My focus is on how research and development (R&D) works in both Jungheinrich and arculus. For others, the focal point might lie in pricing, sales, or production, for example. Lastly, the initiative heavily emphasises building a network. And we're not just talking about connections within the organisation, but also with the current and former graduates.

The graduate programme comprises several cross-functional projects, including at least one with a team located in another country. In the programme's second half, graduates are supposed to initiate a project with their classmates, which we then present to a big audience at Jungheinrich. We also have individual and group coaching sessions to refine our hard and soft skills. Besides these, we can also pick assignments of our choice, giving us enough room to explore.

At the end of the programme, Jungheinrich allows us to opt for the department we liked the most in these 24 months and continue the journey in a full-time role from there.”

And how does your academic background relate to your current role?

Vitus: “My current posting at arculus focuses on the research and development of the arculee, which requires some degree of technical knowledge and skills in robotics. My educational background comes in handy here.”

What was your motivation for applying for the graduate programme?

Vitus: “For me, these initiatives are generally a fantastic way to start a career after university. Therefore, I was already searching for similar opportunities when I came across Jungheinrich International Graduate Programme. What I found particularly interesting about it was the chance I would have to work with robotics. That made it a perfect combination of advanced technologies and my love for robots.”

Vitus brainstorming ideas for the new assignment

Now tell me about arculus. What does your typical day look like here?

Vitus: “First and foremost, I wake up and get ready for work, of course (laughs). I usually arrive at the office around nine o'clock. We have a daily team meeting where we all talk about our tasks for the day. We also share important updates from the day prior and discuss solutions for any potential issues we might face when working on our assignments.

Once the meeting is over, I move on to my responsibilities. Recently, I have been contacting other departments back and forth to get insights and discuss possibilities for a new project, which means plenty of meetings. I have also been working on reviewing past results. On top of that, I get small assignments from my supervisor, like restructuring our product page on Confluence. Or if any task piques my interest, I join in supporting my co-worker(s). For instance, last week, I helped my team member troubleshoot Raspberry Pi (a single-board computer) for product development verification, also known as a testbench.

The best part of my day is between these work responsibilities: the lunch break. I enjoy it because, most of the time, all my colleagues eat lunch together in the common area, and that’s always a lot of fun. As I tick off all my tasks, I pack up and head out to explore the beautiful city of Munich.”

That sounds interesting. What has been your favourite task so far, and why?

Vitus: “I recently attended a workshop at our Gaimersheim office. One of our Senior Software Engineers, Iuri Ferreira, shared some basic knowledge about the arculee, like where and how it is used and who our customers are. I also learned the techniques to troubleshoot the robot on Linux and how to extract useful data. At the end of the workshop, I had a much better understanding of our product.”

And how do you collaborate with other team members in the development of the arculee?

Vitus: “My team is involved with the arculee Backpack, stations, and everything around them, such as the charging station or calibration tools. From time to time, we have meetings and brainstorming sessions. Lately, one colleague had a problem, and we all met the next day to solve it together. I believe discussions like this generate better ideas and solutions.”

Vitus discussing possibilities with Dennis Schradick (Robotics Software Engineer) for his project

How has your experience been so far with cross-functional collaboration and working with team members from diverse backgrounds and skill sets?

Vitus: “I love working in an international environment. I am still getting to know colleagues from different countries, but whomever I have met has inspired me in some way. And here’s a fun fact: most conversations occur around the coffee machine.

Besides these small talks, the bi-weekly sprint reviews have given me some essential insights from all the robotics departments at arculus. I have a fair idea now about who’s working on what and what they plan to do next.”

Can you tell us how the graduate programme encourages personal and professional growth?

Vitus: “With technical assignments, like the project I am working on nowadays, I am improving abilities that I can use in a full-time position in the future. I also have the opportunity to attend workshops and training classes with other graduates, where I can learn and develop leadership and management skills. This initiative will, therefore, also polish my soft skills, such as effective communication, teamwork, and decision-making.”

What are some of the new skills you have developed in a startup environment?

Vitus: “The team meetings have helped me develop critical thinking skills, and my planning has overall become more structured. I’d also add that I have become more adaptable. I think the use of SCRUM methodology at arculus plays a considerable role in fostering these competencies.”

Vitus exploring the insides of our autonomous mobile robot - the arculee

How do you believe this graduate programme creates a synergise between Jungheinrich and arculus?

Vitus: “Post-acquisition, this is a great move to bring both companies together and learn from each other. As a graduate, this is an incredible opportunity to get familiar with both companies, their work cultures, the AMRs, and the team behind them, particularly because my specialization is in the same field.”

What kind of learnings do you expect to bring to your next posting?

Vitus: “From arculus, I will for sure take the workstyle, mindset, and perspective on the topic I am working on. My next assignment will be at Jungheinrich, so I am excited to discover how different their standpoints are.”

To conclude, do you have any advice for potential applicants?

Vitus: “If your focus is not centred around acquiring just technical expertise but also networking and gaining experience in different teams with diverse views, this programme is for you. It will allow you to explore, find the right department, and prove your abilities in various projects.”


February 8, 2023

Safety Standards: An Inside-Look at Human-Robot Collaboration

Safety standards ensure that robots and humans successfully co-exist in the industrial world. Every (AMR) Autonomous Mobile Robot – including our arculee – must meet basic protocols to operate without endangering humans or causing material damage. But what are safety standards, who defines them, and how does arculus incorporate them into its product? This article will answer all these questions and provide insights into the impact of the guidelines for Intralogistics 4.0.

What are safety standards?

Safety standards are a set of guidelines to ensure compliance with robotic specifications. They establish protective measures taken by all agents involved – from the robot's production to customer use. The unique aspect of these guidelines is that any stakeholder (consumers, manufacturers, businesses, research institutes, and public authorities) can propose a standard. It is then reviewed and developed by regional and international experts with full consensus to reach a common standpoint.

"Simply put, safety standards are primarily concerned with protecting workers from hazardous accidents, and regulating the robot’s operation."

Martin Schöpp, our Functional Safety and Automation Engineer, who analyses these protocols and derives requirements for arculus.

A recognised European Standards Organization – CEN, CENELEC or ETSI – sets the rules for all products, services and processes in Europe. These standards are regularly updated to keep pace with advancements in the field. Guidelines for electrical safety of Autonomous Mobile Robots, for example, usually take about five years. On the other hand, general standards that apply to all machines in the EU are reviewed less frequently, usually every 15 to 20 years. This continuous review and updating of processes ensures that technology within the EU is safe, reliable and up-to-date.

Safety features of the arculee

When it comes to the arculee, arculus has integrated various features to prevent on-site injury to warehouse workers or damage to goods and premises. One of its core safety components is the capability to detect humans in close proximity, allowing the robot to behave accordingly. As Martin describes it:

"From the human safety perspective, the main capacity of the arculee is to detect a person around it using LiDAR sensors, also commonly known as safety scanners. It notes the travel speed and direction and uses that to estimate the braking/stopping distance. Based on these three factors, it evaluates if the person is inside the hazardous zone or not."

Close up of the arculee showing the LiDAR sensors, a key feature to ensure safety.
The arculee's LiDAR sensors detect unexpected visitors inside the safety fields in order to act accordingly

Another crucial feature is the robot's ability to identify six types of load using inductive sensors. Each load, including tables and pallets, has a different size and can be transported crosswise or lengthwise (depending on the type) on the arculee. "If a robot does not accurately identify the load type and carries a bigger load than initially estimated, it has a higher probability of crashing into a wall or a human. This is a safety function that truly saves the day.", Martin explains.

In addition to load carrier recognition, the arculee can also detect the placement of pallets via sensors in the Backpack — a piece of equipment mounted on our robot to drive pallets. These sensors are critical to placing the pallets correctly and safely transporting them to their destination. In Martin's words:

"For pallets, we extend the braking distance, and the arculee drives slower. A pallet must be placed on top of the Backpack in the centre to prevent the robot from tipping. Bad positioning can make the arculee lose its balance and potentially damage the load it is transporting. This feature enables our robot to detect if the pallets are in the right position and not drive further to prevent any accidents."

Lastly, our AMR has a safe recovery function for lifting and driving. "When the arculee encounters an obstacle within its safety fields, it signals that it cannot drive further. In such cases, the worker(s) can switch to recovery mode and manually move it out of the deadlock.", explains Martin. In case of system failure or hardware issues, the workers can use a recovery trolley to move the arculee. "The user first needs to switch off the robot to stop it from operating automatically, place the trolley beneath it, and connect the cable to the arculee. The brakes then open, allowing the user to pull the robot to the service area without creating havoc in the warehouse.", he continues.

Close-up of the arculee showing the on and off buttons for manual control
The arculee features on and off buttons for manual control

From Regulations to CE Mark and beyond

The primary purpose of complying with safety standards is ensuring that our AMR meets all requirements to safely drive in the warehouse alongside humans. While arculus has successfully attained various certifications, one of the most significant milestones the company has recently achieved is getting the statement of conformity for the latest version of arculee by the notified body TÜV SÜD Product Service GmbH. This assures that the robot has been developed and tested for safety and complies with national and European safety standards.

"All industrial robots have to provide elementary safety functionality, and the manufacturer can declare conformity and put the CE Mark on the robot. However, not all of them are inspected and tested by a notified body, which ensures that there are no critical bugs implemented. The statement of conformity by the notified body, TÜV Süd Product Service GmbH for the newest arculee generation is a big achievement for arculus and its team."

Romano Wolf (Product Lead - Robotics)

For the accreditation mentioned above, the arculee has to comply with at least four DIN Standards (German Institute for Standardisation), namely DIN EN 1175:2020-10, DIN EN ISO 3691-4:2020-11, DIN EN 12100:1997-11, and DIN EN ISO 13849-1:2016-06.

How does arculus comply with safety standards?

The safety standards are fundamental to building the arculee. For that, it is equally important to test the robot to ensure full compliance. As Martin puts it:

"Quite often, the instructions for testing are provided by the standard itself. For example when testing personnel detection, the standard states which obstacles need to be detected, what we need to place on the floor and where. The guidelines also specify that we should test at full speed and with a 110% overload situation. And if everything runs as expected, the robot immediately stops before hitting the obstacle."

However, when no directions are given, the team is responsible for defining what tests they need to run for safety verification. "Some can be verified by doing calculations like the mechanical strength of the robot. But processes that have to do with the functioning of the arculee, or what determines its behaviour, need to be tested", adds Martin.

Three people standing with their backs turned to the camera. They are looking at two computer screens featuring code. From left to right: a dark haired man, a blond woman, and a brunette woman with curly hair. In the background, a green arculee is visible.
Our Engineers running a test for a new use case

Some of these tests include:

  • Hardware integration tests
  • Type tests for European Conformity (CE)
  • In-Line and End-of-line tests during production
  • Release tests for potential software updates

Training for a safe and sound co-workspace

To ensure that employees are familiar with the latest safety standards, arculus incorporates them into the company's system. This makes them easily accessible to all teams at all times. Additionally, the company conducts regular training sessions led by industry experts to provide employees with in-depth information on the latest guidelines. With that, arculus employees are up-to-date with the latest safety regulations and can apply them effectively in their work.

January 27, 2023

The Future of Logistics: How Intelligent Robotics is Revolutionising the Industry

Logistics operations have traditionally relied heavily on human labour. However, with complex market dynamics, rising operational costs, and a shortage of skilled workers, the need for automation has never been greater. To meet the increasing volume and unpredictable demand, e-commerce and third-party logistics (3PL) companies are looking for ways to streamline their operations and make them more responsive and adaptable. The solution? Flexible and scalable intelligent robotics automation.

Current Challenges in Logistics

Supply chain operations are facing a significant challenge as consumers demand faster and more personalised delivery services. The rise of e-commerce and on-demand delivery services has contributed to this trend, as consumers expect to receive their orders promptly and with accuracy standards. The current economic climate, marked by the COVID-19 pandemic and its effects on global trade, has made it particularly difficult for supply chain operations to meet these expectations and avoid delays and disruptions.

Colourful containers stacked with diagonal shadow.
Cargo containers ready for shipment

In addition to the growing complexity of global supply chains, the logistics industry faces a shortage of skilled labour. This can make finding and retaining qualified workers difficult, leading to increased labour costs and operational expenses. Inaccuracy and inefficiency in operations can also lead to high operating costs, damages, pilferages, and errors, ultimately resulting in reduced customer satisfaction.

arculee to The Rescue

Autonomous mobile robots (AMRs), like our arculee, are at the forefront of intelligent robotics in logistics automation and can address many of the operational and labour-related challenges mentioned above. These autonomous robots can navigate their environment using sensors, marker stickers, lasers, machine learning, and artificial intelligence algorithms while working alongside humans. Here's what AMRs such as the arculee bring to the table:

  • Higher processing speed: AMRs can handle the movement of goods, allowing logistics operations to run continuously for 24 hours with rotations, high accuracy, and energy efficiency.
  • Higher personnel productivity: By taking on mundane and repetitive tasks, the arculees free up human resources to focus on other key areas, significantly increasing personnel productivity.
  • Sustainable workflow: With the help of the arculus software solutions, AMRs can use the most efficient path for material handling while navigating around human workers. This makes the process highly adaptable, sustainable, and energy efficient.
  • Less space required: Many small and mid-sized warehouses and fulfilment centres have limited space. AMRs are more compact than other material handling systems, making them suitable even for smaller logistics outfits.
  • Reduced risk of personnel injuries and damage to goods: AMRs' ability to navigate around other workers and obstacles helps prevent collisions and reduces the risk of workplace injuries and damages.
  • Improved competitiveness: Using intelligent robotics can also help logistics companies stay competitive in an increasingly globalized market. By automating certain tasks, companies can reduce their reliance on human labour and improve their overall efficiency, giving them a competitive edge.
  • Cost savings: While the initial investment in AMRs and AGVs may be high, the long-term savings can be substantial. These robots don't require salaries or benefits; and can work for extended periods without needing maintenance or repairs. This can significantly reduce labour costs and increase profitability.

Bottom line

In conclusion, the future of logistics operations relies on intelligent robotics. From their ability to handle tasks with accuracy and efficiency to the cost savings and improved safety they provide, the adoption of AMRs is set to play a crucial role in the industry's continued growth and success. As the demand for logistics automation continues to grow, integrating these intelligent robots will be essential for the success of logistics operations around the world.

December 7, 2022

Not Just a Fleet Manager: A Deep Look Into The arculus Software Ecosystem

Although the arculee tends to take the spotlight in our portfolio, arculus is as much a software company as a robotics one. With a universal solution, offering a fleet manager and a warehouse administration system, this article will shine some light on the hard work carried out by our programmers in the software team. From simple direction control to large-scale goods-to-person delivery: here is everything you need to know about the arculus software ecosystem.

Let's cover the basics

Software, a word that is so ingrained in the modern world that its meaning feels somewhat forgotten. In the most basic terms, it's a set of instructions, data or programs used to operate computers and execute specific tasks. In other words, software tells a computer how to function.

For the context of arculus, however, the definition is a bit more complex. Martin Krzykawski (Software Developer) explains that "We have a system consisting of two types of subsystems: 'controllers' (the arculus software) and 'agents' (robots). Both of them have their own computer". Each computer runs its own instructions to generate or process "jobs", and they exchange job information via a "communication protocol".

“When we tell a robot what to do, we call it a job. And that job has different actions, like drive here, put your lift up, or get somewhere else.”

Michael Nix (Team Lead Software Warehouse).
The new User Interface of the arculus software ecosystem

But for Martin, there is also a slightly more literal approach to the term. He describes that "software is called software because it's so soft, meaning that you can shape it the way you want to, as long as you do it the correct way". Along these lines, the arculus software presents itself in two different "shapes" according to specific needs. Namely: Fleet Management and Warehouse Management.

Fleet Management

The arculus fleet management solution is an intelligent traffic control system that directs the movement of materials. In layperson's terms, the software works like a navigation app – providing smart traffic management to power and control robots that move products and materials in a production facility.

But when looking at the importance of a fleet manager, one question comes to mind: if the fleet of robots is self-driving and intelligent, why does it need to be controlled by external software? Michael Nix explains that although the robots can drive around using sensors and/or markers on the ground, without the software, they "have no idea what to do or even that there are things to do".

“The fleet manager is the part of the system that tells the robots where to go, in the sense that it gives them a route. It tells them for example, to drive along these points, drive this speed between these two points, or drive the curve there if you can.”

Michael Nix
3D visualization of the fleet manager in action

Looking back at the navigation app analogy, the routing mechanism of the fleet manager also needs a sort of map to calculate the best driving course. For that, the system needs information about the facility, like "where streets are, where intersections are, and which direction along the street robots are allowed to drive", explains Nix. With this knowledge, the fleet manager is then able to locate an available AMR (Autonomous Mobile Robot) to drive along the necessary path.

Warehouse Management – or "goods-to-person"

Martin Krzykawski describes the arculus warehouse solution, as a layer of software added on top of the fleet manager. "The fleet manager chooses a robot and tells it where to go and what to do there (usually transport something from A to B), whereas the warehouse manager finds out what tasks must be done in the first place."

In other words, all the Fleet Manager does is follow routing orders from the higher logic while handling the speed, space allocation and dynamic rerouting of the AMRs if necessary. That means that in a real-life operation, it is the Warehouse Management System that coordinates the transport of parts, in perfect sync with the whole operation.

3D visualization of the goods-to-person concept

The innovative element here is the possibility to eliminate the large distances covered by workers when picking and transporting items inside the production facility. With the warehouse software, AMRs can transport goods directly to the employees at the right time and order. The result is an increase in productivity, accuracy, and space optimisation.

How it all works in real life

Before we go into the details of how the software actually works, let's quickly recap on the uses of the different modules:

Warehouse management software ensures that the materials we need are where we need them at the right time. Fleet management software works out where, when and how to move products and materials.

The combination of both solutions is what constitutes the arculus software ecosystem. This software serves as a single controlling instance for a fleet of AMRs running at any production facility. For that, customers can work with implementation in three steps:

  • Create a digital map of the production facility layout;
  • Use simulation mode to test the developed system for feasibility and performance before the solution goes live;
  • Go live: a real-time overview of the fleet, which now moves in a coordinated dance around the facility.

The Real Action

Of course, customers don't need to work with all two solutions offered by the software – the arculus team works closely with clients to understand their needs and expectations in order to define the best use case. For Michael Nix, that's what differentiates the arculus software solutions from other similar products in the market. "We don't just offer the software for customers to download and install themselves. We have experience integrating custom higher logic and adapting our fleet manager to the needs of our customers.", he explains.

This flexibility comes from the early days of arculus as a company: the partnership with Audi. One of the projects developed in collaboration with the company was the so-called Supermarket 2.0 – one of the first implementations of the goods-to-person sequencing principle in a manufacturing facility.

The arculus software at the Audi Supermarket in Ingolstadt

As arculus solutions were then still new, the cooperation with Audi allowed for the joint development of the arculus software ecosystem. "Normally, you would have to imagine what future customers might need from you while developing your software. Working with Audi gave us the opportunity to battle-test our solution within the real world from the start and evolve it alongside their needs", explains Michael. For that, developers had to build a solution with flexibility at its heart – which is precisely what now allows for higher customisation possibilities than other solutions in the market.

Recognition

One of the proudest moments for our software developers came in 2021 when arculus won the IFOY award in the category of Intralogistics Software.

Founder Fabian Rusitschka (left) receiving the IFOY award in 2021

According to the IFOY test verdict:

"The use of a standardised interface, opens up possibilities for the mixed operation of automated warehouse vehicles that were unthinkable in practice until recently. The fact that arculus Fleet is brand-independent facilitates the selection of the most suitable AGV for a specific transport requirement. Since the system takes into account the current traffic situation on-site for dynamic routings, even higher efficiency and availability is possible."

November 23, 2022

This Initiative Makes Life Much Easier for Working Students

Students often struggle with maintaining a balanced work-study life and finding support from their community. While arculus provides several platforms to connect and interact with colleagues, the Working Student Connect initiative offers more than that. Here's how a small yet significant step makes students' lives easier at arculus.

Connecting the dots

The Working Student Connect is a platform for and by students at arculus to connect, interact, and network with each other. The inspiration came from the arculus Buddy Program, an initiative designed for new hires in full-time positions to facilitate their onboarding process.

"We belong to different departments and, in some cases, different cities. And we, too, sometimes get nervous during our onboarding process and often seek support."

Kerstin Schwering (Working Student People)

With the help of the People's team, our pupils started working on building a community that could be more than just onboarding assistance. They wanted to bring all students at arculus together under one roof. Anika Lorenz (a former thesis student and now full-time employee) describes the idea as "allowing students to network, becoming the support system of each other through the exchange of work routine stories, student life hacks, and hobbies. But most importantly: having fun." In April 2022, the Working Student Connect was created.

Insight into details

Each meeting is half an hour long and happens virtually on a monthly basis. This way, the maximum number of students can participate, regardless of their working locations. There is also a slack channel for communication and coordination with all students, along with a Confluence page with tips & tricks for university life.

Sadaf Hayat (Working Student Social Media) holding a coffee mug while chatting with colleagues outside
Sadaf Hayat (Content Team) enjoying a short coffee break with other students

Every session has an agenda to ensure structure. It includes the rituals of introducing new students, suggestions for ice-breaking questions, discussions about work topics, and a Q&A session at the end. The work matters primarily refer to contract extension, taxes, payroll bureaucracy, open positions for working students, office policy updates, and other organisational subjects.

In case someone brings up a query or problem, students with a similar experience or knowledge are encouraged to help. Therefore, Anika invites all participants to confidently put forward their questions. "Never hesitate to ask because there is always someone who knows the answer. And if you know the right people, you get the answer faster.", she explains.

The fun element

For Kerstin, it’s essential that these meetings include more than just information and organization issues. "They should be fun; no one wants just formal information," she explains. "The purpose of adding icebreaker questions in the agenda, for example, was so everyone could feel comfortable participating. It allows participants to open up to their colleagues and get comfortable with each other," she adds.

For a connection beyond virtual limitations, students are invited to meet outside the office every few months, like at parks or cafes. "It's a good break from work and studies. You keep your worries aside, eat, drink, play games, and get to know your colleagues better.", says Sadaf Hayat (Working Student - Social Media Communications).

Working students enjoying a pizza together
Kerstin Schwering (People’s Team) and Tena Valenta (Content Team) bonding over a shared pizza

The challenge

As mentioned earlier, the working students have their university schedules and priorities, making it a challenge to have them all together in the meeting. "Initially, I spent much time choosing a day and time that could suit everyone's schedule. However, I soon realized it's hard to find a timeslot that fits. Now, the focus is on quality time rather than the number of attendees.", says Kerstin.

Why is the initiative a hit among our working students?

Hassan Saeed (Working Student - Cloud Engineer) finds this platform a great source of help to tackle problems commonly faced by working students. "The initiative is always an excellent way to communicate with all fellow pupils in the company, who tend to share similar issues in life. The meeting helps all of us find solutions in a friendly environment and also provides one more channel for monthly updates about arculus.", he explains.

Tena Valenta (Working Student - Content Creator) also appreciates how convenient these meetups are for discussing the daily challenges of a student. "In our meetings, we tend to talk about everything, from work to random facts and private matters. I admire that everyone is always warmly welcomed and allowed to share their thoughts and queries.", adds Tena

The Working Student Connect meeting in November

All in all

The aspiration of this initiative is not only to keep the working students informed about the company updates but also to give them a point of connection through students from other departments. It also provides them with a sense of belonging through a supportive environment and opportunities to connect and interact with colleagues from the same phase of life.

"We have a page on Confluence and a group on Slack dedicated to the students only, and everyone shares information, tips and hacks that can make our student live less stressful. In a true sense, I see this as a small but meaningful community where we have each other’s backs. Along with other initiatives at arculus, work-study life truly becomes less stressful."

Sadaf Hayat

November 22, 2022

Modular Production: a Story About arculus Founding Vision

Modular Production has recently made the headlines after Audi made public its plans to revolutionize assembly lines in manufacturing. As the founding vision of arculus, it’s time to shed light on this futuristic manufacturing technique. For that, we’ve invited Darshan Patel, Software Developer.

First things first: what is Modular Production?

You may have heard of Modular Production, a concept that promises a new take on manufacturing. Although previously an idea existing only in engineers’ futuristic dreams, it is actually about to become a reality, thanks to the ever-evolving AMRs. While this modern approach promises a lot, it does have to compete against the universally known – and widely proven – assembly lines.

Established more than 100 years ago by Ford Motor Company, the linear production model offered the perfect solution for a market in need of producing uniform products in high quantities. In this configuration, assembling workstations are positioned along a linear path linked by a fixed transportation system.

Nowadays, however, with consumer needs becoming more complex, conventional assembly lines are increasingly struggling with the market’s new dynamic. That’s precisely where Modular Production comes in: as an adaption of traditional manufacturing techniques that “ensures both an efficient large-scale assembly of mixed-model production programs and the needed level of flexibility and changeability to react to variations, disturbances and changes.” 1

The Journey

Replacing a century-old system is challenging and requires a considerable amount of tools. As Darshan Patel (Software Developer) explains, “in a linear assembly line, you might have the fixed transportation system, usually a conveyor belt. But in modular systems, we have Autonomous Mobile Robots (AMRs), like the arculee, that transport parts and products from station to station to push the assembly forward”.

The Prequel

But implementing an optimal modular assembly system requires much more than working robots. As a system that understands manufacturing as a holistic process, it requires a high volume of input data for the planning, such as1:

  • Product portfolio (volume and product mix)
  • Assembly steps per order/product variant
  • Standard assembly time for each step
  • Needed components and equipment for each assembly step
  • Work area at the product for each assembly step
  • Group of assembly steps resulting in one assembly task
  • Assembly priority chart (APC) on the level of assembly tasks for each product

With these answers at hand, the developers can feed the data into software that uses genetic algorithms to provide a set of possible layout plans for the manufacturing facility. For that, it considers variables like codependency relationships between assembly tasks, field restrictions, and fleet size. “The system then shows us, for example, that station x has a heavy workload and should be split into two. And then also, because there is a huge load density in this specific point, we need a better driving network there to avoid bottlenecking.”, explains Darshan.

Modular Production assembly chart after using the planning software
Chart showing the modular assembly system after using the planning software 1

Crossing the Threshold

Only with the layout planning at hand can the Modular Production system be put to work. “It’s like if Modular Production were a movie, it would be parts two and three, and the planning would be the prequel”, explains Darshan.

The holistic manufacturing model itself consists of three different components:

  • Main Modular Production system → controls the assembly of any product in the pipeline. It knows how, when, and where to do any task within the production process;
  • Logistics system → fetches the necessary parts from the storage and brings them to the proper assembly station, at the right time and in the correct order;
  • Worker Management System → assigns the workforce to certain stations according to the production demand, e.g. more workers in stations with a higher volume of goods.

The cooperation between the three systems thrives through simultaneous and mutual optimization. “It’s a delicate dance between these components, which work together to improve the production rate of the whole system”, describes Darshan. “Increasing the speed of transporting components between stations would not work without the simultaneous delivery of equipment to assemble them. And even if you have the right components and pieces of equipment, you still need a suitable amount of workers”, he continues.

The Ordeal

When reading the description of such a well-coordinated system, one question does come to mind: does the whole thing actually work in the real world? The short answer comes from experience – yes, it does, which is currently demonstrated in the pilot project with Audi.

For the pilot implementation, the chosen focus was a door panel pre-assembly. At the Audi Ingolstadt plant, our arculees bring these door panels directly to the station where the components are assembled. “By reducing production time through an orientation toward value creation and self-guidance, we can increase productivity by up to 20 per cent in some cases,” explains Wolfgang Kern, project manager at Audi Production Lab.

Two arculees transporting Audi car doors at a modular production system in an Ingolstadt factory
arculees transporting doors for assembly at Audi’s Ingolstadt plant (Source: Audi Media Center)

The Cliff Hanger

Despite the current success of the pilot, it will still take time until we see a big roll-out in the industry. The reason is simple: “The market is simply not yet ready to accept such a complex and sophisticated system”, clarifies Darshan. But the time and resources invested in the mechanism definitely paid off.

Modular Production is the very root of our current solutions. “Our software ecosystem, for example, is one of our base modules, which controls how we drive and the coordination between robots. And that’s also the base for Modular Production – seamless coordination of AMRs for production tasks”, clarifies Darshan.

Software view of the Fleet Manager

However, one significant outcome of arculus efforts towards Modular Production is definitely the arculee. These autonomous mobile robots (AMRs) navigate freely within a defined area, avoid obstacles and orient themselves when picking up a load carrier by its position and alignment. Although originally developed with manufacturing tasks in mind, such features also fit in perfectly with intralogistics tasks.

As Jungheinrich explains, “the small and manoeuvrable autonomous robot offers a ready-to-use solution for horizontal transport over large areas. This versatile assistant increases throughput and interacts seamlessly with automatic components in the warehouse, immediately improving efficiency in numerous industries and fields of application”.

Two arculus mechanical engineers in front of a computer working on the arculee
arculus engineers at work on the arculee

With these two solutions combined, a third one also comes to life: warehouse automation. This goods-to-person system reverses the traditional picking process by bringing the goods to the employee on autonomous mobile robots, which use the arculus software ecosystem as their central control.

The Moral Of The Story

Although Modular Production is a solution for which the market still needs to be ready, its original concept served as the base for arculus current core products. Namely: the arculee, the fleet manager, and the warehouse management system. Now, with solid solutions distributed and integrated by Jungheinrich, we are ready to help reshape and modernize internal logistics across the globe while also laying the foundations for long-term opportunities with Modular Production.


1 Kern, W., Rusitschka, F., & Bauernhansl, T. (2016). Planning of workstations in a modular automotive assembly system. Procedia CIRP, 57, 327-332.

November 7, 2022

Ramadama: Bavarian Tradition Meets Social Responsibility

If you are not from Bavaria, the word "Ramadama" probably doesn't mean much to you. The term, which roughly translates to "we are cleaning", is used in Bavarian to describe voluntary clean-up campaigns. The goal is to collect trash from public spaces to ensure proper disposal. At arculus, we've decided to come together on the beautiful banks of the Isar river to make Munich a little cleaner and strengthen our team's social bonds.

A Brief History of Ramadama

In 1949 Munich was not as beautiful as it is today. Although the 2nd World War had already ended four years before, the city still had devastating marks of bombing raids. Streets were full of stones and rubble, and many houses were yet uninhabitable. At that time, Thomas Wimmer was the mayor of Munich. He wanted his people to leave the dark years of the war behind and bring them a more optimistic view of the future. But the first step was cleaning up.

So, on the 29th of October 1949, Wimmer called on the people of Munich to clean up together. "Rama Dama!" (We are cleaning) he called, and over 7500 volunteers answered. Men, women, children, and even the mayor himself picked up shovels to free the city from the dirty scraps of the war. Together, the population removed more than 15,000 cubic metres of rubble that day, and Munich soon looked more beautiful again.

Since then, "Ramadama" has stood for joint clean-up activities. With the support of local Waste Management Companies, voluntary citizens from all kinds of different groups come together all across Bavaria to make their cities cleaner.

Bottle caps and cigarette butts contain toxic chemicals that can harm nature

The arculus Team Clean-Up

So, to honour our Bavarian roots and commitment to social responsibility, some members of the arculus team decided to get together for our very own Ramadama gathering. The chosen location was the beautiful banks of the Isar river, not far from our headquarters office.

Just like every arculus gathering, the event also offered a fun possibility to tighten the team's bonds in a different setting. "It was much more than just picking up trash. We even created a collaborative playlist to make sure that we could make it a fun social happening.", says Maria Souza (Social Media Coordinator).

For some new joiners, like Johannes Maier (Robotics Engineer), it was also a possibility to get to know some colleagues for the first time. "It was fun to walk along the Isar with the new colleagues and to do something good for the environment at the same time", he explains.

The arculus hero cleaners getting their hands dirty

Like any Ramadama action in Munich, the arculus clean-up had support from AWM (Munich Waste Management Company), who provided the cleaning materials and assisted with the general organization. Kristina Frank, Municipal Officer and First Works Manager of AWM, explains, "A Ramadama like this is a great community experience. All these people are thus voluntarily taking responsibility for cleanliness in their home city. AWM is therefore very happy to support this sustainable civic engagement to preserve Munich's recreational areas."


Want to join our next event? Then apply to one of our open positions here!

November 3, 2022

Voices of the Team: Maria’s Experience as Social Media Coordinator at arculus

Acceptance, strategy, and trust: learn how these three keywords come together to define Maria's experience as a Social Media Coordinator at arculus.


Hey Maria, welcome to our interview! First things first: can you explain what are your main tasks as a Social Media Coordinator at arculus?

I'm actually responsible for taking care of arculus presence online. That includes our social media channels, of course, like LinkedIn and Instagram. But also our online presence in general, our website and our blog as well.

My goal is to make sure that as many people as possible get to know who arculus is, what we stand for, what we do, and who we are. That includes potential customers but also potential joiners for our team.

When people think of a social media coordinator or manager, they usually think of someone who spends all day on Instagram or TikTok. But the job is actually much more than that, I get to think strategically, and I need a lot of organizational skills, but in the end, I really like what I do.

Focused at work

And what do you appreciate most about working at arculus?

First of all, being an immigrant in Germany, for me, it's really important to actually get to know more people, and everyone at arculus has been so nice to me so far. And all of the social events are also a great plus.

But also, as a member of the LGBTQ community, it feels amazing to be able to bring my full self to work, not having to hide a part of me. That makes waking up and going to work much easier every day. And, of course, the work-life balance is also a great plus for me. Being able to take care of myself outside 
of work as well, and this whole combination of things makes it easier and makes me feel good working here.

What arculus value do you most identify with?

Definitely trust. It's really good to know that I'm trusted to do the job I was hired for. So no one is really questioning my decisions towards what I think is better to fulfil our strategy and my tasks. And also, relating to time management, there's no one really checking how many hours you're working. No one really cares as long as you deliver what you're supposed to. And that's really different from 
what I have experienced so far in other companies.

Maria at the Werksviertel, where the arculus office is located

And one last question: what excites you the most about the Jungheinrich acquisition?

I actually come from quite a strong corporate background. So, for me, it feels a bit like "going back home". I really appreciate how these big companies have people all over the world who are working 
towards the same goal, so you actually get to meet people from different cultures and understand how they work. And, of course, the safety that comes with a big corporate job is also a nice bonus.


Watch Maria's full video interview below:

November 2, 2022

The arculus Buddy Program: A Step Towards a Greater Employee Experience

New hires are sometimes nervous or hesitant to address concerns and ask for assistance. There is some amount of stress which is natural yet overwhelming. That is where our six-month Buddy Program comes in - to facilitate integration through a social approach. This article will cast light on the process, its benefits to the team, and its guidelines, all from the perspective of arculus employees.

The buddy program is an onboarding initiative to familiarize new joiners with the company's culture, processes, standard protocols, and policies with the help of experienced colleagues. The program has been in place since 2020, thanks to the efforts of the arculus People's team.

“The aim is cross-functional development, enrichment of the employee experience, and good integration of recruits within different teams.”

Afiffa Batool (Talent Acquisition Recruiter & Partner)
Our buddies are always excited to welcome new joiners

How does the initiative work?

It is a six-month voluntary program, which requires a minimum of three meetings with half an hour each. Participants are free to hold sessions anywhere; it can be on the office premises, outside, or even online (depending on the location of both participants). "Most of the time, I am in the Gaimersheim office and only a few times in Munich. That's why I have had almost all of my buddy meetings online. But once, when we were both in the same city, we finally got to meet and talk over lunch.", explains Jonas Jaeger (Production Engineer).

The people's team takes three factors into account when selecting buddies. The first is if, after the end of their probation period, the employee wants to volunteer for the program. The second is to ensure that the participants are not in the same team so that the new joiner gets as comfortable with other groups as they would be with their usual peers. It also opens avenues to learn and understand what other departments are working on. The third is if the new employee works totally remotely, then they must get a buddy who works from the office. That allows them to see how everything is done at the workplace without feeling left out.

The program has no formal template to follow, and the meetings generally occur in an informal setting. "For me, it's always a casual meeting where we introduce ourselves. I explain a bit about the company, who is who, and my own experiences. It is also an opportunity to get more familiar with the other person.", describes Lisa Bell (Content Creator).

The idea is to lend ears and shoulders to the new colleagues; therefore, there are no final goodbyes. "In theory, your job is done after six months, at the end of your peer's probation period. But, for me, it is not a job; I see it more like being there and supporting that person," says Maria Souza (Social Media Coordinator). "You can for sure meet and talk as often after it ends.", adds Lisa.

Fabian Na and Lisa Bell having a good laugh in one of their buddy meetings

Nonetheless, participants need to keep certain principles in mind. As someone's buddy, one is not supposed to review the job performance, be a subject matter expert, or be expected to know everything. Buddies should offer encouragement and support, give honest feedback, provide suggestions for more efficiency and productivity, and keep the shared information confidential.

What makes the buddy program a symbiotic relationship?

Maria recalls how the buddy program facilitated her transition when she joined the team in January 2022. "It was nice to have someone to explain how arculus works and give me a positive outlook regarding what awaited me at this job."

Fabian Na (Mechanical Engineer) reminisces how this program gave him his point of contact in the company. "My buddy made me feel comfortable and introduced me to everyone. She also gave me a little background on what had happened in the company so far and explained a bit about the arculus culture."

Nevertheless, Fabian also believes it is an equal opportunity for the buddy to learn something new. "Now, being a buddy myself, I understand the company's culture better. Also, I get to give them information on how the company is and get to know that person better, especially if they're in a different department."

The buddies are active listeners

Like Fabian, Lisa finds the program a medium for connecting with other teams. "I'm always curious about what's happening in the other departments. What are they working on now, and what are their challenges? It also allows me to understand our products better as they continuously develop."

Reasons why our employees approve of it

Based on an internal company survey, arculus has received a positive response from the employees. They agree that this program helped them achieve a smoother onboarding process, better understand how other departments in the company function, and develop soft skills like networking.

"You develop many more connections in cross-functional teams. Without the program, many colleagues wouldn't have a clear vision of how processes work in other departments, or even what they're working on. Now, thanks to this creative initiative, we all have a much better understanding of the roles and responsibilities of the other colleagues."

Lisa Bell, Content Creator

TL;DR

The buddy program, in a nutshell, is a low-maintenance solution that has helped new joiners at arculus with integration. It provides them with a safe space and time to learn about the company culture, values, and operations through an experienced fellow worker. By combining it with other social and technical integration and onboarding initiatives, we provide possibilities for engaging with colleagues and improving knowledge about the company as a whole. As a result, we have well-informed and motivated employees with higher productivity rates right at the end of their onboarding process.

October 26, 2022

9 Futuristic Warehouse Automation Facts That Might Surprise You

Rising labour expenses, workplace safety, labour availability, and a growing desire for speedy order fulfilment; these are all driving forces behind the warehouse automation trend. Now, with more distribution centres turning to robotics, intralogistics centres that don’t invest in technological development will be left behind when it comes to efficiency.

We've compiled a list of 9 intriguing stats about the dynamics of warehouse automation to show you why now is the time to invest. From space optimisation to increased accuracy, these stats demonstrate why the future of warehousing has already begun.

General Market Stats

1. The Autonomous Mobile Robot (AMR) Market size was valued at USD 1.61 billion in 2021 and is predicted to reach USD 22.15 billion by 2030

This accounts for a projected CAGR (Compound Annual Growth Rate) of 34.3% from 2022 until 2030. The ever-increasing use of these robots across various industries is largely due to their capacity to navigate independently in dynamic environments. Furthermore, the rising use of automated material handling and trends such as lights-out automation are likely to drive market expansion during the projection period. (Source)

Our arculee transporting pallets

2. The investment in intralogistics robotics is increasing

According to Logistics Management research, 10% said that they currently use AMRs or AGVs, and 23% are evaluating them for use within the next 24 months. Last year, that breakdown was 6% who currently use, and 14% considering them. “The simplest way to describe the overall findings from this year’s 'Annual Warehouse and Distribution Center (DC) Equipment Survey' is that it’s “go-time” for investment in warehouse automation.” (Source)

Does your company currently use, or are you considering, automated guided vehicles and/or robotics technologies for materials handling applications?

Source: Logistics Management, all rights reserved

3. 96% of industry leaders consider innovation essential for growth

Deloitte’s study defines innovation as an understanding of how the investment in it will pay for itself over time. It also explains that supply chain leaders know that “innovation is necessary if a company wants to shift the trade-offs between service levels and costs, rather than simply move along the curve.” (Source)

4. The top 3 areas for using robots in warehouses today are picking, goods receiving and unloading, and sorting

The study conducted by Peerless Research Group (PRG) in March 2022 shows that “the top priorities for using such technology includes picking (42.9%), goods receiving and unloading (42.9%) and sorting (37.5%). About 43% of companies are considering AMR pallet movement equipment while 34% want autonomous retrieval-to-person/put-wall robots, and 30.2% are evaluating robotic picking systems.” (Source)

Optimization Stats

5. Travel time in a warehouse can account for up to 50% of the picking time

Without automated solutions, workers must manually pick orders by hand and carry them across the intralogistics facility. With our goods-to-person robotics solution, picking efficiency can be increased two-fold. (Source)

6. Robot’s contribution to labour productivity in the 90s and 00s was about 0.35% per year

While that doesn’t seem much, specialists explain that it is comparable to the growth brought about by the steam engine during the years 1850 to 1910. Now, with technology reaching new higher standards, this number is likely to increase further. (Source)

7. 79% of organisations with better supply chain capabilities, the so-called “supply chain leaders”, achieve above-average revenue growth

Deloitte surveyed more than 400 executives in manufacturing and retail across the globe and found that superior supply chain capabilities tend to translate into above-average performance on revenue growth and EBIT (Earnings before interest and taxes) measures when compared to the industry average. (Source)

8. Warehouses are now nearly 3 times as large as they were 15 years ago

“The average size of warehouse in 2000 was about 65,000 sqft, whereas now it is over 181,370 sqft. As warehouses demand more space, this naturally pushes up the price. In fact, between 2011 and 2015, warehouse rental rates were up by a whopping 28%”, states a Westernacher Consulting report. According to the same research, increasing land costs are also one of the main drivers for intralogistics automation. (Source)

3D rendering of a warehouse with optimised space use

9. Automated and efficient warehouses are 76% more likely to boost inventory accuracy to 99% or higher

The survey conducted by Aberdeen Group with over 250 supply chain executives also shows that with “Systems assisting humans, rather than humans directing systems, best-in-class distribution centres are also able to achieve 95% on-time deliveries, one and a half times more often than average.” (Source)

Wind Up

The numbers don’t lie, the automated future has begun. But fear not; there is still time to join the race towards more efficient intralogistics. If you are ready to get our arculees up and running in your warehouse, head to Jungheinrich’s product page for a personalised solution consultation.

CONTACT

arculus GmbH
Balanstrasse 73 
Haus 10
D-81541 München

info@arculus.de