Manufacturing Automation
Move More. Handle Less
ASRS and automated sortation keep parts on time, cut manual touches, and keep lines flowing, even in tight spaces and temperature controlled environments, so you hit takt with fewer stops and less overtime.
US-built, with local service and fast spare parts.
Throughput
Up to 600 dual cycles/hr
Specs
1.5s transfer
30″ x 20″ totes
Process
Simulation-first sign-off
Origin
U.S. manufactured
Why This Works
Buffers WIP and finished goods, releases material by priority, and feeds lines at the right time without adding travel. OPEX ASRS systems suit tight footprints and temperature-controlled areas.
Deterministic routing sends the right tote, tray, or carton to the best next step. Automated sortation balances stations, protects takt during changeovers and micro stoppages, and lifts accuracy.
Timed hand-offs between cells that prevent choke points. Integrates with existing conveyors and controls to keep operations at the cell.
Workflow Software
An integration software suite to allow our systems to integrate into any OMS, ERP, or MPS, etc.
What Operations Leaders Get
- Throughput per labor hour up, without adding heads
- Walk and wait time down, operators stay at work cell
- Line side stockouts down, kitting accuracy up
- More production in the same footprint
- Stable, predictable flow you can schedule and staff against
Where it Fits
- Line side replenishment and supermarkets
- Kitting for assembly in automotive, aerospace, and electronics
- Post process buffering and pack out for CPG and food and beverage
- Spare parts and aftermarket fulfillment inside plant or DC
- Lot tracking, QA holds, and rework loops without choking flow
Our Process
Throughput Assessment
Share SKU mix, volumes, takt, shifts, and constraints. We model ASRS feed rates and sortation logic against your lines and identify choke points.
Design and Integration
Define tote sizes, inference points, coding, and control logic. Keep what works, insert ASRS and sortation where impact is highest, and add Tote IO only where it removes handling.
Pilot to Scale
Stand up one flow cell, validate KPIs, then expand across departments with minimal disruption.
What Smart Teams Ask
In a majority of cases, no. We design to your current environment and phase upgrades where ROI is clear. There may be a small number of cases where existing conveyance cannot accommodate.
Yes. The software layer exchanges only what is required for priorities, confirmations, and exceptions.
Every tote or load is tracked through the ASRS and sortation with scan or vision checkpoints for full genealogy.
Third-party conveyance responsibilities and warranties are defined up front. Roles and boundaries are clear so there are no surprises.
Performance is engineered, not assumed. We simulate aisle length, tote heights, device counts, and I/O locations. Acceptance criteria are agreed upon before installation.
OPEX proudly manufactures its automation solutions in the United States, leveraging in-house capabilities across machining, welding, painting, and proprietary assembly processes. With facilities in New Jersey and Texas, OPEX supports global demand while investing in local talent through training programs and advanced technologies.
Industry Use Cases
Automotive and Heavy Equipment
- Stabilize kitting to protect takt during model changeovers
- Feed mixed-model assembly with right time totes
Electronics and High Mix Assembly
- Short runs, many SKUs, tight takt, traceability required
- Reduce walk miles and balance stations with deterministic routing
Food, Beverage, and Cold Chain
- Automate tote movement inside cold rooms to reclaim capacity
- Reduce door open time and labor exposure in low temp zones
Get My Throughput Estimate
One minute form. You get a tailored estimate with modeled feed rates, labor impact, likely constraints, and expected gains.
What Happens Next
We run a quick model of feed rates, buffers, and likely choke points across ASRS, sortation, and transfers.
You receive a simple throughput estimate with assumptions and expected gains tied to your takt and SKU mix.
If the fit is strong, we propose a pilot plan with clear acceptance criteria.
Clear roles for conveyance and warranty boundaries are defined up front. No surprises.