Case Studies — Ki Robotics

Chennai · India

ABC Containers Ltd.

FMCG · 84 SKUs

Doubling IML container production with full robotic automation

Tier 1 FMCG container manufacturer wanted to double output without doubling floor space. We deployed 14 KI-IMR-7800 robots across 8 IMM lines with integrated Ki·Cortex monitoring.

+108%

Output gain

-78%

Defect rate

-42%

Labour cost

11 months

ROI payback

Stuttgart · Germany

Werner Automotive GmbH

AUTOMOTIVE · EV

EV battery pack assembly for a Tier 1 European OEM

28 collaborative robots integrated into a new EV battery pack assembly line. Cycle time targets met in commissioning. Full IATF 16949 documentation delivered.

94s/pack

Cycle time

99.6%

First-pass yield

28

Cobots deployed

11 weeks

Commissioning

Nagoya · Japan

Tanaka Medical KK

MEDICAL · IMPLANTS

ISO Class 7 cleanroom robotics for cardiovascular components

Cleanroom-compatible robotic cells producing high-precision cardiovascular implant components. Full UDI traceability through Ki·Cortex from raw material to finished pack.

ISO 7/5

Cleanroom class

100% UDI

Traceability

24/7

Production

FDA-ready

Validation

Detroit · USA

Continental Tier 1

AUTOMOTIVE · BIW

Replacing legacy automation with a unified Ki platform

Brownfield retrofit of a 1990s-era body-in-white line. Old PLCs and disconnected robots replaced with Ki·Cortex orchestration and KI-IMR-7800 arms.

-67%

Downtime cut

+19pp

OEE jump

4

Lines retrofitted

14 months

Project duration

Singapore

Nexus Semiconductor

SEMICONDUCTORS

Cleanroom wafer handling for advanced semiconductor packaging

ESD-safe robotic wafer handling integrated with vision inspection. Zero contamination events in 18 months of operation.

+44%

Throughput

0 events

Contamination

100% inline

Inspection

99.94%

Yield

Madurai · India

Golden Bricks

BUILDING MATERIALS

Modernising a second-generation brick manufacturing operation

Bilingual Tamil/English ERP module with Ki·Cortex Lite deployment. Sales, inventory, vehicle dispatch, and GST compliance unified in one system.

-78%

Manual hours

Real-time

Order visibility

Automated

GST filings

Sub-₹10L

Cost

São Paulo · Brazil

Plastilatina S.A.

FMCG · MULTI-SITE

Robotic palletizing across three plants in a regional rollout

Standardised palletizing automation across three plants. Same Ki·Cortex deployment, three sites, central federated reporting.

1,800 cases/hr

Throughput

3

Sites unified

Unlimited

Patterns

13 months

ROI

Sydney · Australia

Pacific Logistics Co.

LOGISTICS · WAREHOUSING

Autonomous warehouse with 45 KI-AGV vehicles

Brownfield warehouse retrofit with SLAM-based AGV fleet. Existing infrastructure preserved, no magnetic tape, no fixed paths.

45

AGVs

+62%

Throughput

99.97%

Picking accuracy

Unchanged

Floorplan

Real factories. Real outcomes.

Operations transformed

Doubling IML container production with full robotic automation

EV battery pack assembly for a Tier 1 European OEM

ISO Class 7 cleanroom robotics for cardiovascular components

Replacing legacy automation with a unified Ki platform

Cleanroom wafer handling for advanced semiconductor packaging

Modernising a second-generation brick manufacturing operation

Robotic palletizing across three plants in a regional rollout

Autonomous warehouse with 45 KI-AGV vehicles

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