B A N S I L A L R A M N AT H A G A R WA L C H A R I T A B L E T R U S T ’ S

V I S H WA K A R M A I N S T I T U T E O F T E C H N O L O G Y
A N A U T O N O M O U S I N S T I T U T E A F F I L I AT E D T O S AV I T R I B A I P H U L E P U N E U N I V E R S I T Y

Subject : Mechatronics
KARAKURI WITH SHOOTER WAGON
IOT FOR HOME AUTOMATION

Presented By:
Shivam Lohar (P-32)
Under the guidance of : Jai Patel (P-46)
Prof. Dr. Girish Kotwal Devashish Rathod (P-54)
KARAKURI
• Karakuri is the art of creating machines
without an external power source.
• Power Management
• A karakuri device needs power to
function, or, more generally speaking, it
needs energy. Rather than using a
dedicated power source like a motor,
karakuri devices take their energy
wherever they can get it from. Here are
some examples of where to get energy,
how to store it, and how to get rid of it.
 Principles of Movement
You convert movement from one form into other forms. Besides changing directions, this means
converting back and forth between rotational movement, linear movement, swinging, and intermittent
rotation or even magnets.There will be all kinds of gears, ropes, pulleys, cams, cogs, bars, links, belts,
The principles of Karakuri Kaizen are:
• Don’t use the human hand. Move objects automatically.
• Don’t spend money.
• Use the force of your equipment.
• Build it with the wisdom and creativity of the people of the shop floor.
• For safety, don’t just rely on paying attention, but build a device that
stops automatically.
Benefits of Karakuri devices:
• Less expensive – Development time is shorter, materials are less costly (as
there are often fewer items involved), and the energy costs are much less
(if any).
• Easier to maintain – With less costly parts, and more knowledge of how it
works, keeping these devices running is simpler.
• Easier to improve – Since it is built by hand, it can be changed quickly
which promotes continuous improvement
• More engagement with team – More people can help build a karakuri
device, rather than outsource it to another company. Employee
engagement is greater.
• Improved safety and ergonomics – Reducing the chance of worker injuries
and loss work days
• Improved quality – devices reduce human error and mistakes
Conventional Automation VS KARAKURI
 About the Project
• William and his team were asked
to create a demonstration of
shooter wagons. the LMP sales
team – to communicate the
benefits of this material handling
solution to prospective customers.
Chuter

• Flexible to modify to meet varying

working conditions
• Suited for use as shelves to store supply
parts and works. A convenient chuter can
be created when corocon parts are
combined. Angle and shape customization
is possible to fit any type, number or size
of container.
• Even large-size chuters, being lightweight
and easy-to-move, require minimum
workload for transport.
 About Shooter Wagons
• Shooter wagons are a type of gravity-flow rack, combining
storage and material handling in one system. They operate
via a first-in, first-out racking order, meaning boxes move
to the forefront only after the preceding one is removed.
• Shooter wagons are cost efficient and help companies to
maximize space and efficiency while saving time, space,
and manpower. They’re ideal for lean manufacturing
environments and used in many applications, including
material handling, storage, picking, and assembly lines.
• Shooter wagons are a viable material handling solution based
on several properties they exhibit:
• They’re easy to dock.
• They automatically pass off full boxes and receive empty boxes
after docking.
• Compared to manual solutions, shooter wagons load and
unload much faster.
• And lastly, these wagons are inexpensive and simple to
maintain compared to pneumatic and electric systems.
• Shooter wagons are a type of karakuri device, meaning they’re
mechanically powered and don’t require electric, pneumatic,
or hydraulic power to operate. They use gravity to process
boxes.
• “Shooter wagons are an ideal solution for any business looking
to enhance productivity, improve workplace safety and save
money,”
• “While they’re a simple and cost-effective solution.
 The Shooter Wagon Animation
• The mechanics and ingenuity of the karakuri devices. The
animation demonstrates the shooter wagon concept in a
simple material-handling example:
• “In the demo, the material handler prepares the kit in
boxes and places them on the gravity roller tracks on the
top level of the shooter,” . “These are basically angled
tracks that allow the boxes to slide down using gravity.”
• “When the shooter is full, it is transported to the
production area, either manually or by an automated
guided vehicle (AGV).”
• At production, the shooter trolley is docked at the material
shelf. Upon docking, the shooter automatically gives the
prepared kit boxes to production while receiving empty
ones. After the exchange, the shooter trolley goes back to
the kitting area to be filled again
• “You’ll notice that when the boxes hit a
mechanical stop, they’re waiting to be
transported down a level,” said William.
• “The weight of a box at this mechanical stop is
used to signal a raise of the tilt-elevator up one
level. When the tilt is raised, it hits a mechanical
switch, allowing the box to slide in.
• The weight of the box is heavier than the
counterweight, and the tilt shifts downward.”
• When the wagon comes together with the
material shelf in production, a mechanical sprint
is lifted, allowing boxes to flow between the
gravity rollers of the shooter and the shelf.
• The exchange is performed automatically, using
nothing but gravity.
AGV with Karakuri
• Here an AGV moved material
around. The material was stored
on rolling lanes on the AGV. The
AGV supplied a supermarket next
to the assembly. Simply by driving
slowly past the supermarket,
different levers activated the
material transport, and boxes with
material moved from the AGV into
the supermarket, while empty
boxes moved back to the AGV.

• Heavy labour
• Many transportation tasks for workers
• Risk of serious traffic accident, human error
• High stacking = unsafe, no FIFO principle
• Large space only for temporary storage
• Unmanaged WIP, intermediate inventory
• Unstable supply timing
• Reduction of physical hard work
• Avoidance of serious accidents and errors
• No stacking = Safety, tidy and FIFO principle
• Reduction of temporary storage space
• Establishment of One-piece-flow, WIP control
• Reduction of lineside structures = shortening
production line length and lead time
• Intermittent operation, partial speed change of line,
stable supply at certain time interval
Project Outcomes and Benefits
• “It is helping LMP to profile itself as
using market leading demo tools
and technology,” “This can be done
during customer visits but also fairs,
conferences, and trade shows. It’s
easy to see which method is more
effective and impactful for the
customer.”
• https://youtu.be/nUf2EjXy-OI
• https://global.sus.co.jp/business
/fa/karakuri/unit-movie05.php
• Demo 1 -
https://youtu.be/BIt0eZ1a5eA
• Demo 2 -
https://youtu.be/1fBup5ffyWg
References
• https://www.robotcenter.co.ukhttps://global.sus.co.jp
• Mechatronics/AGV20info
• https://www.susamericainc.com
• https://www.industr.com
THANK YOU !