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’Increased efficiency and easier working conditions – KUKA robots’ contribution to the daily routine at CIE LT Forge
“When robots are introduced, people will lose their jobs” – such concerns were voiced at the "CIE LT Forge" factory in Marijampolė about a decade ago when the company decided to pursue automation. However, today the automotive industry company employs a similar number of people as it did back then, and the fears have long since disappeared.
CIE Automotive group
The 15 KUKA robots working in the modern forge are seen as helpers rather than competitors, and even employees prefer to work on the robotic lines. Roboticization has also led to a significant increase in line productivity. "CIE LT Forge," part of the international "CIE Automotive" group, produces various forged components weighing between 0.7 and 12 kilograms for the automotive industry. Among its clients are world-renowned car manufacturers such as Audi, Volkswagen, and Renault.
From Manual Labor to Smart Automation - Previously, manual work dominated the production process at "CIE LT Forge." “Inserting a blank into a press, removing it, and transferring a hot, heavy forged part to the next production step – all of this was done manually,” recalls Darius Masionis, CEO of UAB "CIE LT Forge." “If we hadn’t committed to robotics ten years ago, we wouldn’t be competitive today. The decisions we made were the right ones, and we made them at the right time,” he affirms. Last year, another production line was automated.
Built to Withstand Harsh Conditions
The successful automation project was implemented in cooperation with KUKA, a global leader in robotics and automation solutions. "CIE LT Forge came to us with a clear goal – to automate their production processes, specifically focusing on hot forging lines and loading/unloading operations," explains Dalius Grakavinas, KUKA’s Regional Manager for the Baltic States. KUKA robots are used across various industries – from automotive and electronics to furniture assembly, food, and beverage production.
Dalius Grakavinas, Country Manager Baltics
Remarkable Growth in Production
“At the Marijampolė factory, our robots operate under harsh, even extreme conditions – high temperatures, metal dust, and specific chemical substances dominate the production environment. But the robots are designed to endure these challenges and work efficiently and reliably,” notes Grakavinas. The results speak for themselves – production volumes at the company have increased significantly.
Until 2017 the entire plant had only one robot working on a crankshaft line, with a production capacity of about half a million units, according to the "CIE LT Forge" CEO, Darius Masionis. After installing a fully automated forging line, crankshaft production rose to over 1 million units. “For example, last year our production on this line reached 1.3 million units. That’s roughly a 160% increase in capacity. The small forge line increased by about 75%, and other forging lines by around 30%,” Masionis reports.
Video CIE
Increased efficiency and easier working conditions - the contribution of KUKA robots to the daily routine at CIE LT Forge
Physically Easier and Safer Working Conditions
Beyond increased output, another key benefit of automation is improved and safer working conditions for production operators.
“Of course, manual labor in forges had its challenges: heat, heavy lifting, metal dust, and so on. Now the hot metal blanks, weighing 10–20 kilograms, are transferred by robotic arms to the next production stages. Workers are distanced from these hot spots – making the work physically easier and much safer, says Grakavinas.
Darius Masionis, VD CIE LT FORGE
Darius Masionis adds that workers now prefer automated lines over manual ones. Another positive trend is lower turnover among employees working on these lines.
Naturally, operators’ qualifications have also improved significantly. “Now operators need to think more, coordinate processes, and oversee them, rather than just lift parts mechanically. We train all our employees to work with robotic lines and invest heavily in their development. Some have even undergone training in Spain, learning how to operate in this environment,”
Digital twins and a glimpse into the future
KUKA also develops software like KUKA.Sim, which enables companies to create digital twins – to simulate production, test automation scenarios, and analyze their impact on productivity. “Companies can simulate how robots change specific operations, evaluate their efficiency, and make informed decisions on whether automation is worthwhile. It’s a powerful tool for strategic planning,” says Grakavinas.
Meanwhile, "CIE LT Forge" is already looking ahead to the era of electric vehicles. "We are now observing that there will be an increasing need to shift from internal combustion engines to the production of components for electric vehicles. Therefore, we are evaluating automation opportunities in this area," says Masionis. KUKA's vision is even bolder: “Someday, we might reach a point where we turn off the lights, go home, and return in the morning to find a warehouse filled with completed parts,” Grakavinas says with a smile.
