June 11, 2024    |    9:30am - 3:30pm

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June 12, 2024    |    9:30am - 3:30pm

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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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ctrlX – The Automation Ecosystem That’s Two Steps Ahead; The Smartphone of Automation


A whole new world of automation is emerging. Because rigid, complex automation systems no longer meet the requirements in markets that are characterized by ever shorter product life cycles and ever fiercer competition. In addition, it is important to exploit the potential of digitalization and networking by combining control technology, IT and IoT in a meaningful way.

The Internet of Things (IoT) is considered the driver of the future in industry. With it, real production landscapes are merging with the digital world across the entire value chain. The boundaries are becoming increasingly blurred. This development is also changing automation.

The increasing networking and merging of automation technology and information technology is clearly bringing the topic of cyber security into focus. Resilient systems that are resistant to attacks are indispensable in the factory of the future.

ctrlX AUTOMATION surmounts the classic boundaries between machine controls, the IT world and the Internet of Things. With a Linux real-time operating system, consistently open standards, app programming technology, web-based engineering and a comprehensive, secure IoT connection, ctrlX AUTOMATION reduces components and engineering costs by 30 to 50%.

As a consistently open automation platform, ctrlX AUTOMATION provides all the building blocks for complete automation solutions with the ctrlX World ecosystem. The system is modular, scalable and covers the requirements for almost all applications as needed. Automation without limits.

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The Manufacturing Technology Centre (MTC), Coventry, CV7 9JU June 11, 2024 9:30am - 3:30pm BOOK NOW
The Manufacturing Technology Centre (MTC), Coventry, CV7 9JU June 12, 2024 9:30am - 3:30pm BOOK NOW
Thanks to the team for an awesome workshop, it was a great an no-nonsense practical demonstration of Lean and Industry 4.0 combined. I can highly recommend this workshop.
Oliver Buhlinger, New Intelligence
New Intelligence
Fantastic Day
Kirsty Eastwood, Rolls Royce
One of the most effective workshops on Lean I have been to in years. The team at Lean Workshop Group have put together an excellent practical demonstration, delivered by industry experts to help any business take their early steps into Lean to the more experienced who wish to consider I4.0.
Sam Thiara, MCS Control Systems
Very enjoyable day. Thank you and well done
Paul Fox, Denso Marston
A good all round experience
Paul Stratford, Cell Pack Solutions