Systematic intermediate buffering:
How workpiece carriers avoid bottlenecks on machines and increase process stability
In production, it is not only the processing time that determines efficiency, but also how components are handled between processes. Intermediate buffers are an often underestimated factor here – they ensure cycle time, avoid machine downtime, and relieve the burden on operating personnel.
In reality, however, many intermediate storage facilities are not standardized: loose parts in boxes, makeshift storage or non-stackable containers complicate the processes.
ZELL Part carriers offer a structured solution for this – stackable, robust, modular, and precisely tailored to the component and the process.
🎯 Challenge from the perspective of production management
Machines stop because components are not available on time. Rework is caused by damaged parts in the chaotic buffer.
Personnel has to manually repack components – this costs valuable minutes per cycle. Variants must be separated elaborately, which leads to errors with similar parts.
Clear traceability is hardly possible if components are not stored in a structured manner after a standstill or rejection.
✅ The solution: Part carriers as a structured buffer
ZELL Part Carriers perform multiple functions simultaneously: They ensure precise component pick-up, protect sensitive surfaces, and enable seamless traceability. Standardized stackability ensures space-saving intermediate storage directly at the machine.
Defined receptacles enable automated removal – robots access parts with precise positioning. Refilling by the operator is not required. Components are precisely fixed and remain stable – ideal for optical components, threads or ESD-sensitive parts.
Each carrier can be equipped with RFID, engraving or DMC, and each position is clearly traceable in the ERP or MES system – perfect for process-reliable series production.
Application examples for intermediate buffers with workpiece carriers:
🛠 CNC / Milling
Stacked & buffered directly after processing – without transfer or repackaging.
🧼 Cleaning
Carrier travels directly through the washing or drying process – without media disruption.
🔍 QA / Camera test
Components are tested & documented with positional accuracy – ideal for traceability.
🤖 Assembly / Robotics
Robots remove parts directly from the buffer – reliable & automatable.
🚚 Internal transport
Part carriers are stackable and can be used directly on AGVs or trolleys.
Advantages for your production - concretely measurable
- Fewer machine downtimes, as components are ready for cycling
- Reduced personnel costs for transfer and picking
- Less waste due to secure hold & no contact between parts
- Less space required, as carriers are stackable and standardized
- Greater transparency, as each carrier can be tracked in the system
Conclusion for Production Managers
ZELL Part carriers are not packaging – they are a tool.
They secure your cycle time, protect your parts, and connect machines, processes, and logistics into an efficient overall system.
👉 No repacking. No loss of space. No surprises.
📩 Request consultation now – we will show you how to introduce intermediate buffers with a system and save costs sustainably.
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