Shape Corp. Pilsen: A Benchmark for Smart Automation in Intralogistics

January 2025

As a leading vendor of crash management systems, the US-based company Shape Corp. supplies renowned OEMs such as Nissan, Toyota, and Renault. For its new facility in Pilsen, Czech Republic, an automation-ready layout was a fundamental requirement right from the design phase. With its comprehensive approach and continuous support throughout the change process, idealworks quickly emerged as the ideal partner to optimize the plant’s intralogistics, while also addressing the growing skills shortage. At idealworks, the focus extends beyond merely providing an automation solution. The company supports clients through every stage – from analyzing current processes to standardizing them and optimizing workflows – ensuring maximum efficiency in automation deployment. This approach was also applied to Shape Corp.’s automation journey, with particular emphasis on standardization. Through close collaboration, idealworks developed a standardized solution for transport dollies, enabling the autonomous mobile robots (AMRs) to independently move any dolly, regardless of the load.  

The results are outstanding, the technology works perfectly, and our employees are able to integrate it intuitively into their daily operations.” – Tangui Cheneviere, Automation Expert Shape Corp 

Robotics Ecosystem Transforms Intralogistics  

Previously dependent on manual tugger trains, the plant transitioned to a fully automated process. Four iw.hubs, idealworks’ undercarriage AMRs, are now in use, centrally orchestrated by the intelligent automation platform, AnyFleet. This system facilitates seamless transport of empty packaging to the production area and the movement of filled containers to the shipping area. 

Challenge of Mixed Traffic 

One of the main challenges for automation solutions lies in environments where automated and manual vehicles must work in tandem. While the iw.hub comes standard with a range of safety features, manual vehicles often lack such safeguards. To ensure maximum safety, idealworks incorporated the Safety Guard System from Linde Material Handling into the automation solution. This system adjusts the speed of manual vehicles automatically, minimizing the risk of collisions between forklifts and AMRs. As a sales and service partner, Linde Material Handling is one of several key collaborators in idealworks’ robotics ecosystem, enabling the rapid implementation of the assistance system 

Attractive Employer Through Automation 

Beyond solving logistical challenges, automation has significantly improved the overall work environment. Employees have been relieved from repetitive, physically demanding tasks, allowing them to focus on more complex duties. The replacement of manual tugger trains with AMRs has also led to a substantial reduction in noise levels in the plant, positively influencing the work atmosphere. 

It makes our employees proud to interact with the technology of tomorrow everyday.” – Gregory Houdayer, Plant Manager at Shape Corp. 

Maximized Efficiency with Automated Intralogistics 

Since early 2024, four iw.hubs have been operating in a three-shift system, up to six days a week, with minimal maintenance requirements. With approximately 90 transport missions per shift covered by the AMRs, Shape Corp. has significantly enhanced both safety and efficiency in its intralogistics processes. 

Following this success, efforts quickly began to double the number of iw.hubs and, consequently, the filly automated missions per shift in the coming months.  

With the implementation of idealworks’ robotics ecosystem, the Pilsen site has become a technological showcase for the U.S. parent company, as proudly emphasized by Plant Manager Gregory Houdayer. 

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