The CTS Perspective is a new regular column from the engineers at cts Group, exploring how industry really automates and digitalises – one practical insight at a time.
In electronics manufacturing, material flow is rarely simple. SMT reels, trays, Euro Boxes and PCB magazines often coexist within the same production environment, each with different handling requirements, movement patterns and protection needs.
The challenge is not the existence of multiple carrier formats — this is standard in most modern factories. The real challenge is creating a storage and transport system that can manage these differences efficiently without introducing operational confusion, lost traceability or production delays.
When mixed storage environments are not properly structured, inefficiencies quickly appear. Storage locations become overcrowded or underutilised, carriers are misplaced, and operators spend valuable time searching for material rather than supporting production. In many cases, inventory technically exists within the factory, yet the production line still stops because the required carrier cannot be located quickly enough.
The Problem with Treating Every Carrier the Same
One of the most common mistakes in mixed storage systems is applying the same operational logic to all carrier types, despite their very different physical and process characteristics.
PCB magazines, for example, are sensitive to orientation and handling conditions. Euro Boxes may be stackable and robust, while trays often require different access and staging methods. When all carriers share identical return routes, storage areas and handling processes, ambiguity increases and process reliability suffers.
This typically results in:
- Poor space utilisation caused by rigid storage structures
- Increased search times and unnecessary handling
- Incorrect returns and material misassignments
- Reduced traceability
- Greater operator dependency and process inconsistency
These problems are often gradual rather than dramatic, which makes them particularly difficult to identify until production efficiency is already being affected.
Structuring the Differences
Successful mixed storage systems do not attempt to eliminate differences between carrier types. Instead, they create clear operational rules around them.
Effective systems classify carriers according to their handling, protection and movement requirements. Frequently accessed materials are positioned close to line-side handoff points, while sensitive materials are managed within protected or dedicated storage zones.
The key is establishing clear rules for:
- Storage locations
- Handoff points
- Return processes
- Status tracking
- Exception handling
This creates a material flow structure that operators can easily understand and follow without relying on informal workarounds or tribal knowledge.
Transport systems and storage equipment must also support this flexibility. AMRs, conveyors and storage fixtures need to accommodate different carrier sizes and handling requirements without creating special cases for every format change.
Traceability and Process Visibility
Reliable traceability is critical in mixed storage environments. Material movements should always occur through defined process points rather than informal manual handling.
In practice, this means maintaining clear visibility of:
- Carrier type
- Current location
- Process status
- Return path
- Line assignment
When integrated correctly with MES and ERP systems, mixed storage environments become scalable and highly controllable rather than operationally complex.
Conclusion
A mixed storage system should not be viewed as a compromise. When properly designed, it becomes a structured and scalable intralogistics solution that supports production efficiency, process stability and long-term growth.
At cts, mixed carrier environments are approached through clear storage architecture, intelligent transport integration and process-driven operational logic. By structuring carrier differences instead of ignoring them, manufacturers gain improved visibility, reduced operational ambiguity and a material flow system capable of supporting increasingly flexible electronics manufacturing environments.
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