Cooperation between KUKA and KLEUSBERG: Automated Manufacturing in Modular Construction

KUKA, a global leader in automation, has partnered with KLEUSBERG, a leading expert in modular construction and mobile space systems, to drive modernization and automation at KLEUSBERG’s production facility near Halle (Saale).

As part of this collaboration, beginning in 2027, floor and ceiling frames for modular buildings will be produced using a highly flexible, robot-based welding system. The turnkey system, delivered by KUKA, will leverage advanced automation technology to enable production that is nearly fully automated.

Five KUKA robots weld more than two thousand meters of floor and ceiling frames

At the core of the system are five independently programmed robots, designed to manufacture customized frames with high precision. Spanning more than 1,000 square meters, the production area enables efficient operations, with the system expected to weld over 2,000 meters of 2D frames each week.

“In addition to increasing efficiency, improving working conditions played a significant role in the decision to automate, aiming to reduce health risks for employees caused by physically demanding postures. Furthermore, new technically oriented job roles are being created,” says Oliver Hartmann, Managing Director of Modular Construction at KLEUSBERG.

Digital and automated – for flexible and efficient production

Automatic collision checks before production begins and seamless data integration with other factory systems ensure smooth and reliable operations. “In robot-based automation, achieving maximum precision is always the top priority. The system can accurately position each component and visually inspect weld seams to ensure quality,” said Andre Zander, Key Account Manager at KUKA Systems Assembly & Test.