How one robot delivers three‑shift performance, cuts costs, and brings stability to production

 In September 2025, we commissioned a robotic palletizing workstation at DH Dekor, designed for handling furniture components coming off a CNC router.

The goal was clear: replace physically demanding, repetitive work, increase production stability, and deliver measurable savings.

Today — after several months of continuous operation — we can confirm that these types of robot installations absolutely make sense. Not only technologically, but especially economically.

How the solution works

The robotic workstation is designed to handle the entire palletizing operation fully autonomously: Handles a wide range of part dimensions: from 100 × 100 mm up to 2000 × 400 mm A collaborative FANUC robot with a 30 kg payload ensures safe and reliable operation Flexible palletizing schemes — longitudinal or transverse, including layer shifting along both X and Y axes The system automatically calculates trajectories, offsets, and stack heights based on entered dimensions User‑friendly HMI interface (Siemens) allows fast and easy setup Automatic height measurement of the panel stack ensures accuracy and reduces errors The robot can be quickly detached and moved aside if manual operation is needed The result? Stable 24/5 performance without the need for a second operator. How much did it reduce costs? Before installation, each CNC shift required two operators. After deployment: Only one operator is needed — and can also configure the robot Minimal maintenance interventions Stable performance with only a 5–7% decrease in productivity, which is completely normal for collaborative robots This reduces labor consumption from 2 man‑hours to 1, bringing a clear cost saving.

Benefits for the customer DH Dekor now benefits from: Replacement of an operator in continuous 24/5 operation Reduced operating labor costs High variability of handled parts Smart trajectory calculations and automatic corrections Easy operation without programming — handled by one operator Very low failure rate — only minor issues handled by regular maintenance Quick switch to manual mode when needed

What does the customer say?

"The robot runs 24/5 and all issues were negligible — just routine maintenance.

Once, we had a part where the height measurement caught a groove, but a small adjustment solved it.

The operator now sets up both the robot and pallet balancing alone.

We no longer need a second operator.

Output dropped by 5–7%, but we cut labor from two man‑hours to one.

Economically, it’s clearly a plus. Payback? Low tens of months."

Why this is the path of modern manufacturing

Projects like this prove that automation doesn’t have to mean massive robotic lines or multimillion‑euro reorganizations.

Sometimes all you need is:

• a well‑designed process,
• the right technology,
• and simple, intuitive control.

The outcome is a solution that:

• relieves people from physically demanding work,
• increases stability,
• delivers cost savings,
• and achieves payback in months, not years.

Want a similar solution in your production?

We’ll show you exactly what it could look like — from the first idea to commissioning.

Just like at DH Dekor: simple, fast, and with a clear economic benefit.

Get in touch with us.