Person designing modular aluminum profile systems in CAD software on a laptop, surrounded by blueprints for conveyor systems, partitions, and workbenches. Manual and configurable production systems

Ready for efficient production? We will show you how our modular components make your shop floor flexible and future-proof. Your shop floor, our solutions. Efficient, flexible, future-proof – today and tomorrow!

Modular, manual production workstation on the shop floor with configurable flow rack systems, conveyors, and industrial equipment Tailor-made production optimization. Made by Bosch Rexroth.

Inspiring application examples. Tailored solutions. Maximum effectiveness for your production.

Bosch Rexroth Aluminum Chameleon Adaptable for any application. Watch the video View of an efficient workstation with ergonomic parts supply from Bosch Rexroth Level up your manual production

Find the right solutions for your manual or semi automated lines.

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Manual and Configurable Production Systems

Modular application solutions made of aluminum for efficient production processes

The demands on production and intralogistics processes are growing continuously. Companies from the automotive industry, the semiconductor sector, the consumer packaged goods (CPG) environment, warehousing, and mechanical engineering are faced with the challenge of aligning their value creation efficiently, flexibly, and in a future-proof manner.
What is needed are scalable, economical solutions that grow with the company.

We develop modular application solutions made of aluminum that can be precisely integrated into existing production and material flow processes. Our portfolio includes manual and configurable production systems ranging from cobot stations and ergonomic workstations, to FiFo stations and Kanban flow racks/supermarkets, to material shuttles, packing and picking stations. Our application solutions are based on proven, field-tested standards that can be individually adapted, expanded, and scaled.

This results in tailored production solutions that adapt to your processes, not the other way around.
The result: Maximum effectiveness, investment security, and a shop floor that grows with your company.

Thanks to our extensive engineering expertise and our global, certified partner network, we support companies of all sizes in designing high-performance production environments – from SMEs to corporations – reliably and in partnership. Modular aluminum solutions enable ergonomic workplaces, efficient material flows, and scalable intralogistics structures that impress today and grow tomorrow.

Mobile workstation with worktop, gripping container, monitor. Top-mounted camera and 2 information boards

Ergonomic workstations

Discover how our configurable workstation solutions seamlessly combine geometry, functionality, and ergonomics. From flexible design to integrated material supply - our concepts enhance motivation, productivity, and quality.

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Trolley with 4 material levels, handrail, castors, and information board. In the front, an aluminum frame with tabletop on 4 vertical aluminum profiles and horizontal aluminum crossbars at the bottom.

Material shuttles

Optimize your logistics with our configurable material shuttles for all types of transport options. Ideally suited for Kanban systems, they offer ergonomic adaptability, ESD variants, and maximum flexibility for dynamic production processes. Increase transparency and efficiency on your shop floor.

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Rectangular table with cabinet elements. Metal table with mounted robotic arm

Cobot stations

Our configurable cobot solutions enable the seamless integration of collaborative robots into your production. From modular design to ESD versions, they open up new potential for automation and human-robot collaboration on your shop floor.

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FiFo station with locking mechanism for material shuttles in guide rails. 6 stations with multiple infoboards and material feeders. 5 material shuttles, each including 2 adjustable material levels. 4 floor rollers with a box. 4 infoboards across 4 guide rails.

FiFo stations

Maximum efficiency and sustainability for your material flow. Our versatile system, ideal as a supermarket shelf or directly at the workstation, optimizes processes through the FiFo principle. Customizable in color and dimension, it offers maximum reusability and tailored efficiency.

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Mobile rack system with 2 infeed and one return level, 4 rows each, roller sections suspended in aluminum frame.

Kanban flow racks/supermarkets

Efficient material supply with flexible adaptation. Whether as a supermarket shelf or directly at the workstation – our system optimizes material flow through FiFo and Kanban. Modular use, a wide range of color schemes, and individual dimensions ensure the perfect, tailored solution for your production.

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Rectangular protective fence, enclosure with integrated cobot station and transfer system.

EcoSafe safety fences

Protect your personnel and your systems with the modular EcoSafe safety fence systems from Bosch Rexroth. These high-quality and flexible safety solutions offer maximum stability, simple mounting, and perfect adaptation to your production environment.

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Flow rack system with worktop. Rear construction with several shelves that include divided vertically positioned plates for separating material. Tilted to the right and left. Roller rail system for material supply from the rear in the middle and bottom. On the right, aluminum extension for various attachments. Mounted light on top.

Packing stations

Optimize your packing processes with the packing stations from Bosch Rexroth. These ergonomic and individually adaptable workstations enhance efficiency in packing, reduce manual strain, and ensure smooth operations. Discover the benefits of a flexible packing station that perfectly adapts to your requirements.

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Workbench for order picking with integrated point rollers for moving the material. In the foreground, a material shuttle with 2 material levels. In the background, a middle and upper level on an aluminum frame.

Picking stations

Increase efficiency and precision in your material supply with Bosch Rexroth picking stations. These ergonomic and individually adaptable workstations ensure error-free order picking, optimized workflows, and ultimate ergonomics for your employees.

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We are here for you

Do you have questions or need further information? Our experts are available to provide you with individual consulting.

Contact us

Our Framework for your efficient production

Employee is working with Bosch Rexroth Engineering Software MTpro

Services & Processes

Using our MTpro planning software, we assist you throughout the entire implementation process. Also we will guide you throughout the entire lean production process. The MPS philosophy is rounded by Bosch Rexroth's short delivery times and process flexibility, enabling you to make your thoughts on lean production a reality without any waste.

Bosch Rexroth workstations with manual linked EcoFlow, Lean, ESD.

Lean manufacturing

Based on the three pillars of the Manual Production Systems covering workstations, material supply and linking, you can create, for example workstations, as well as entire production lines, that can be quickly adapted to your work content and executed in an extremely efficient manner and avoiding waste in line with "lean" principles.

Man standing at workbench

Ergonomics

An ergonomic workstation design plays a decisive role in reducing waste during production. From an ergonomic aspect, the main focus is on the worker. This is why the workstations from Bosch Rexroth are designed to fit each worker and not the other way around.

Bosch Rexroth ESD pictogram

ESD protection

Electrostatic charges develop as a result of electric charging generated by friction on various materials or by induction in electric fields. They can then discharge and damage or destroy sensitive components. We offer a large selection of products to protect your products from damage caused by ESD.

Discover more applications

Explore more solutions from Bosch Rexroth.

Application dynamic seating and its typical movement sequences while working

Swivel Chairs

  • Chair design for all areas of use
  • Supports the S shape of the vertebral column, lumbar support
  • Use of environmentally-friendly materials

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7-axes collaborative robot arm

Kassow Robots - 7-axes collaborative robot arm

  • The five lightweight 7-axis cobots from Kassow Robots are ready for use in next to no time and are suitable for companies of all sizes.
  • They have a payload of 5 to 18 kg and achieve a reach of 850 to 1800 mm at a joint speed of up to 225 degrees per second.

More about Kassow Robots

Success Stories

Success Story Manual Production Systems LTI/Levitec

Increased poductivity at shorter cycle times

Handy lean production units consisting of the EcoShape tubular framing system and aluminum profiles from Bosch Rexroth for the production of high-speed drives.

Success Story Manual Production Systems Berlinger

Healthy employees are more productive

Ergonomic, height-adjustable assembly line from Bosch Rexroth ensures flexible and efficient manufacturing processes for tamper-proof packaging systems.

Are you ready to optimize your production processes?

Get in touch with us – we look forward to your inquiry.

Frequently asked questions about Manual and Configurbale Production Systems from Bosch Rexroth

What do Bosch Rexroth's manual production systems (MPS) stand for?

They are developed strictly in line with lean principles to avoid waste and to enable the quick planning and realization of lean production facilities.

What are the three pillars of MPS?

Workstations, material supply, and linking – these allow individual workstations and entire lines to be efficiently adapted.

How does Bosch Rexroth support the planning and implementation?

With the MTpro planning software throughout the entire implementation process, complemented by short delivery times and flexible workflows.

What ergonomic advantages do the workstation solutions offer?

The workstations adapt to the employees (e.g., height-adjustable), reduce fatigue, and increase productivity; swivel chairs support the lumbar spine and promote dynamic sitting.

Are there ESD protection solutions for production?

Yes, a wide range of ESD products reliably protects sensitive components from electrostatic discharges.

What is EcoFlow designed for?

For material flow at and between workstations as well as in the warehouse/picking area; it reduces strain as products are transported on manual conveyor tracks.

What distinguishes the EcoShape round tube system?

Poka-yoke design, anti-rotation protection, and combinable connectors (including D28, D28L, N10) enable easy and secure assembly.

Can I configure individual workstation solutions?

Yes, you can choose between tailor-made solutions based on parameters or standardized products – for targeted resource use and higher productivity.

Where can I find products and documents?

In the Rexroth Store and in the catalog (PDF); videos on workstations and flow rack systems are also available.

What are the advantages of the LED basic system luminaires?

They are 50% brighter with 20% lower energy consumption and enable up to 50% lower investment costs in tri-light configuration.