Boosting Free Pallets Automation for Speed and Scalability

Summary

Sept. 10, 2025 – Flexible, modular workpiece transport can bring valuable extra speed to automated assembly with free pallets. Scalability is also enhanced, while built-in tracking provides traceability data to meet the requirements of demanding industries such as automotive.

Manufacturing companies often need to scale their capabilities and capacity quickly to meet the demands of customers serving high-volume markets such as automotive components, building automation and IoT. Winning a tender to supply original components to a big automotive brand is a major coup for a parts maker and is a cause for celebration. On the other hand, the win also challenges the supplier to meet obligations that are often complicated and can demand careful investment in new automation. The customer may order a relatively small number of units to test the water before placing major orders, and there may also be a ramp-up period.
 
A small business needs to be smart to manage the transition from being the winning tender to becoming a trusted long-term partner. Financially, making a large up-front investment in new equipment may not be feasible and risks being left with over-capacity if the business ultimately goes in a different direction. On the other hand, they need to be ready to deliver according to the agreed schedule as soon as they get the green light.

Free pallets automation

Free pallets is a flexible and scalable approach to automated manufacturing processes. Using free pallets automation is widely appreciated as a flexible approach to manufacturing products continuously, in high volume. The workpieces are mounted on pallets that move independently between workstations, usually on a conveyor or track system. They are not rigidly fixed and can be stopped, rerouted, or buffered as needed.
 
In a typical free pallets process, automated equipment at each station performs a specific task on the workpiece carried by the pallet, such as welding, assembly, or inspection. The pallets move asynchronously, each at their own pace, depending on the time taken to complete the process or availability of the next station. Pallets can be diverted to different paths or stations based on the product type, quality checks, or production logic. Because the pallets can queue between stations, upstream and downstream processes can operate at different speeds.
 
There are inherent advantages in this approach that are of particular benefit to small manufacturers. Extra stations can be added quickly and cost effectively, or unneeded stations removed, without redesigning the whole line, thereby easing scalability and letting businesses adapt as customers evolve their requirements. Also, by directing different products to follow different paths, small businesses can support mixed-model production and customise individual units if required. In addition, by decoupling the process timing between stations, automation with free pallets minimises bottlenecks and ensures resilient and maintenance-friendly manufacturing. If one station stops working for any reason, other stations can continue.

Automation with standard conveyors

Automotive components, smart heating controls and other engineering assemblies are often produced this way, enabling manufacturers to optimise flexibility and uptime. In an EV battery assembly line, for example, the battery modules are placed individually on their pallets and move through the sequence of processes. The first process may perform an automated inspection before the pallet moves to the next station for automated screwdriving. The final station then completes the sequence by laser welding the battery pack. If the welding station is busy, the pallet can wait or can be rerouted to an alternate welding cell.

Upgrading the concept

Free pallets has proved effective in numerous manufacturing scenarios. Yamaha Robotics has worked with the systems integrator El.Mec, from northern Italy, which has created modular manufacturing cells for free-pallets processing using robots from the extensive Yamaha SCARA portfolio. The cells leverage an innovative design with standardised external electrical and mechanical interfaces that can be connected directly to other cells when the time is right to extend the production line for increased production output or faster throughput. This lets equipment operators scale-up their production lines even more quickly and easily than is possible in a conventional free pallets line.
 
The cellular concept helps manufacturing companies bid for large contracts despite having only limited capacity, confident that they can accelerate throughput and adapt individual processes as needed to fulfil their obligations throughout the lifetime of the project. Each cell contains a set of production stations and, by integrating Yamaha SCARA robots, these stations ensure fast and efficient cycle times when assembling and handling workpieces such as valves and small mechanisms. The stations can be manually withdrawn for maintenance, adjustment or adaptation if required.

Faster and more flexible

By also integrating the Yamaha LCMR200 linear transfer system (Figure 2), the latest generation of this standardised cell can operate at a higher line rate than is possible when transporting the workpieces using conventional conveyors. Powered by linear motors, the LCMR200 sliders travel at up to 2500mm per second. The speed, acceleration/deceleration, and stop positions are programmable, and therefore easy to setup, fine-tune, and adapt as needed.

Conclusion

Free pallets automation is a proven manufacturing technique that delivers flexibility for operators and can scale when needed to increase production capacity and throughput. Further enhancement, introducing standardised, interconnectable production cells and Yamaha’s linear transfer system unleashes extra speed and faster scalability, to let small manufacturers handle big contracts more confidently.

About Yamaha Robotics FA Section

Yamaha Factory Automation Section (FA Section), a subdivision of Yamaha Motor Robotics Business Unit in Yamaha Motor Corporation, is focused on delivering flexible, high-accuracy industrial robots for precision automation challenges.
 
With its roots in the introduction of robot technology to Yamaha motorcycle assembly activities, the division has over 40 years’ experience solving automation challenges from factory-scale to micron-level. Yamaha’s industrial robots are now trusted by leading corporations worldwide, in activities as diverse as semiconductor fabrication and assembling electronic products, domestic appliances, automotive components, and large liquid-crystal panels.
 
Yamaha Motor FA Section offers a unified range of solutions for robotic assembly, including single-axis robots, SCARA, cartesian, and articulated robots. Innovations such as the LCMR200 linear transfer system; a smoother, space-saving and more versatile successor to conventional belt and roller conveyors continue to set the pace in factory automation. Core robotic technologies as well as key components and complete robot systems are all produced in-house, ensuring consistent quality and control over lead-times. Headquartered in Neuss, Germany, Yamaha FA Section serves customers in all Europe.