The 3 pillars of Manual Production Systems from Rexroth

The main concern of modern production is to avoid waste. The MPS Manual Production Systems from Rexroth have been developed strictly in line with aspects for lean production, enabling simple and fast planning and implementation of lean production installations.

The demands on modern, lean production are more than just focusing on individual modules. In fact, an integrated system with a uniform implementation concept comes to the forefront. At Rexroth, this concept is reflected by the MPS philosophy.


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.

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Rexroth will guide you throughout the entire lean production process. Using our MTpro planning software, we assist you throughout the entire implementation process.

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The MPS philosophy is rounded out by Rexroth’s internal processes. Short delivery times and process flexibility enable you to make your thoughts on lean production a reality without any waste.

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ESD protection

Electrostatic charges develop as a result of electric charging that is generated by friction on various materials or by induction in electric fields. They can then discharge at the workstation and damage or destroy sensitive components.

Rexroth’s ESD program offers a large selection of products to protect your products from damage caused by electrostatic discharge.

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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 these workstations are designed to fit each worker and not the other way around.

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Intelligent Cordless Nutrunner Nexo

Rexroth offers precise tightening technology – tools, control systems, and the corresponding accessories – for all key tightening tasks in a wide variety of industries: from the intelligent cordless nutrunner Nexo, the ergonomic handheld nutrunner ErgoSpin, the versatile tightening spindles, to fully automated tightening solutions.

The Rexroth Nexo for safety-critical fittings under VDI/VDE 2862 ensures maximum freedom for use with consistently high reliability. It is the first cordless screwdriver with integrated control and power electronics that can reliably work with fittings even in WIFI dead spots. In these instances, the detailed processing results, including curve data, are buffered by the integrated control system and transmitted wirelessly to the receiver station at a later time.

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Operator Guidance System

Digital operating instructions minimize errors and improve process reliability as part of complex, safety-critical assembly and tightening applications. Bosch Rexroth’s Operator Guidance System supports production workers by displaying digitally produced operating instructions on a monitor. This reduces errors and improves process reliability and product quality as part of the assembly process.


The Operator Guidance System displays every step in the assembly process and provides instructions on how to correct identified errors. Once the assembly work has been completed, it saves all the results and provides full process documentation. The data are then available for end-of-line approval and for full traceability purposes.

The virtual guidance system runs on standard PCs running the Windows 10 operating system, optional in conjunction with a touch display. The parameterization of the operational procedures does not require any programming knowledge. The system is also very flexible as users can not only integrate Rexroth nutrunners and spindles but also various different types of tightening-specific hardware such as socket trays and torque wrenches or even employee ID cards and scanners. An optional pick-to-light system also identifies the bolts and components required for the job. The visualization prevents rework due to incorrect instructions being used and prevents time lost searching for work instructions.

What’s more, multiple stations can even be configured from one access point. Furthermore, fixed, stationary work stations and work steps in continuous flow production can be interlinked.

The Operator Guidance System can be integrated into different planning systems and even complex ERP systems without the need for elaborate interfaces.

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ActiveCockpit – Interactive communication platform for the manufacturing industry

Efficient production processes require continuous improvements, particularly in an ever more networked, highly-variable factory environment. For optimal fault and quality management, it is important for users to have fast access to complete and comprehensive data. ActiveCockpit enables them to react quickly with minimum effort – both on production lines and within the company.

A glimpse at typical manufacturing processes demonstrates how many different data sources the user has to take into account: Information regarding stock and pending orders have to be retrieved from the PC in the production planning department. Condition and quality data are documented manually on various boards. Users maintain their personal calendars individually on their own PCs. They also have to be able to operate the user interfaces of the line control and various machines as well as start processes manually.

Via open interfaces, ActiveCockpit can continuously gather, processes and filter all the manufacturing data from existing system environments and other external data sources. The latest quality and manufacturing key figures can be displayed in real-time and can be directly analysed by the appropriate staff either on a line-side touchscreen or in a meeting environment.

ActiveCockpit is completely interactive: whiteboard, escalation, e-mail, explorer, and up-to-mobile functionalities facilitate a more efficient decision making process. Data history is retained to enable trend analysis and it can also be annotated with doodles or text and distributed to the appropriate staff to ensure that the right information gets to the right people to make the right decisions within the world of lean continuous improvement.

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IoT Gateway – Get ready for Industry 4.0!

Many plants and machines have not yet arrived in the digital age. They first need to be connected in order to be able to make use of the benefits of the Industrial IoT. The solution is the IoT Gateway that you can use for existing installed equipment as well as for new machines.

The IoT Gateway makes your machine and process data more transparent. Real-time monitoring of process data such as temperature, pressure, vibration etc. ensure that your production is consistently of high quality. Rule-based analysis of specific information simplifies predictive and plannable maintenance of your plants.

You can configure and commission the IoT Gateway software quickly, conveniently and completely free of programming via the integrated web interface – without intervening in the automation logic. Connection to a multitude of data sources and IT systems possible – solutions ranging from sensors to the cloud.

It is completely secure by integration of a Firewall and VPN network segmentation, protection against unauthorized access by third parties and setup of a VPN tunnel for secure remote maintenance.

Bosch Rexroth offers the right hardware for the efficient and cost-effective integration of IoT solutions – from sensors to high-performance IPCs.

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Fantastic Day
Kirsty Eastwood, Rolls Royce
Very enjoyable day. Thank you and well done
Paul Fox, Denso Marston
A good all round experience
Paul Stratford, Cell Pack Solutions