Every system we develop at Esypro starts with a layout designed to make processes clear, safe, and efficient. Today, we want to introduce Melisa, Project Manager at Esypro, who brings over eleven years of experience to the company. Throughout her career, she has gone through different stages, from the initial project design to team coordination, giving her a comprehensive perspective on every project.
In this conversation, Melisa explains how her journey translates into efficient layouts, strategic decisions, and solutions that truly make a difference for our clients.
Could you tell us a bit about yourself and your professional journey at Esypro?
When I first joined Esypro, everything was new to me. I came from the civil engineering world, where I worked on structural calculations for bridges and tunnels, which is quite different from what I do today. Still, that foundation helped me a lot: I was able to apply my knowledge to the sizing of the structures we build and propose different challenges and solutions.
I started out in project design, but gradually I became more involved in defining and coordinating teams. That path has led me to where I am today: working as a project manager.
To start, how would you simply explain what a layout is and why it’s so important in intralogistics?
I see it as the system’s map: a schematic that shows the space it needs and how components will move within it. Having a good layout is key because it ensures everything flows in an orderly and efficient way.
When a client contacts Esypro, what minimum information do you need to start working on a realistic layout?
The first thing is to have the client’s layout to understand the available space and where the system will be installed. We also need to know the loading points and where the items will be consumed.
Another key aspect is the pieces themselves: their geometry, weight, and how they are stacked. If there are different types, we request information on each to define the load unit—its shape, weight, and quantity that the system will handle. The greater the diversity of pieces, the more complex the design. Additionally, it’s essential to understand the working method: supplying items in batches is very different from supplying them sequentially. This detail directly affects how many items each load unit can carry.
Finally, we need to know the cycle time—that is, how often an item needs to be replenished. With all this data, we can determine the best solution, whether manual or automatic, and present the proposal that best meets the client’s needs.
Do you always have all the information needed to create a layout?
Although it may seem surprising, we often don’t have all the information from the start. In complex projects, like Esyair systems with a wide variety of items, it’s not always possible or feasible to have detailed data for every geometry.
In these cases, we make an initial estimate of space and capacity—enough to propose a technically and economically viable solution with a clear, simple flow, which is what the client cares about most at the beginning. Later, in more advanced phases, we do need all the precise information to adjust the proposal and define the system’s actual capacity.
What criteria help decide whether a client needs a manual or an automatic system?
In most cases, the decision depends on the client’s budget. When there’s little variety in items, a manual system is usually sufficient. But as diversity increases, an automatic system becomes more practical: it delivers the right item to the right place without the operator having to manage everything, reducing errors and ensuring a more reliable supply, among many other advantages.
Buffers or accumulation zones are often mentioned. What key points should be considered when sizing them?
Typically, the buffer size is defined by the client when requesting a technical proposal, or sometimes it’s dictated by their end customer. For example, some OEMs with simple automatic systems for a single item work with a 30-minute buffer. In other cases, stocks of up to two days are requested. We always try to guide the client and analyze whether those two days are necessary to avoid oversizing the system.
Which structural or space-related aspects usually most constrain an intralogistics design?
Generally, the available space is the biggest constraint. Rarely does a client say, “Use all the space you need with no restrictions.” Normally, we supply items at floor level, while accumulation is done on a second level, allowing the client to use all or part of the space under the platform for other processes.
In more complex layouts, with many robots or machines on the floor and limited space for columns, we use stronger structures with truss beams, reducing the number of columns and leaving more free area to work. In fact, this is the solution that has been most widely used recently.
How do you approach projects where the client’s initial layout is not viable?
It’s true that sometimes a client prepares an initial layout for technical and economic analysis, but it’s not always viable. Not everyone knows our product in detail enough to propose a fully functional design. In these cases, the initial layout serves as a starting point: it gives us an idea of what they want. With precise information about how they work and the limitations that exist, we can redesign the solution so it’s buildable, works optimally, and meets their expectations.
It’s crucial to know how they operate and what they need beyond their idea of what we can do. Only then can we advise them as efficiently as possible.
In your experience, what surprises clients the most about our solutions?
In my experience, clients are most often surprised by the simplicity and effectiveness of some solutions that don’t seem obvious at first. I recall a recent case in the U.S. with an automatic system we were installing. The client already had a system from another provider and explained how they wanted ours to work based on what they knew.
During installation, my colleagues noticed some operations being repeated in the other system, and I asked the client why they were done that way. Once we understood what they really needed, they were pleasantly surprised: our system automated movements they previously had to do manually every day. This is possible thanks to our software development with a Windows-based database, not just PLC, giving automatic systems more complex logic and allowing them to perform more functions, among other advantages.
Do you notice a trend among clients toward more modular and scalable layouts to adapt to future changes?
Yes, definitely. Our systems, both manual and automatic, are easily expandable, and clients look for that advantage from the start. Since I joined Esypro over 11 years ago, many projects have been developed in multiple phases, sometimes covering the entire process of an item—from injection to final assembly and delivery to the production line.
If you could give one piece of advice to a client starting to think about their intralogistics layout, what would it be?
My advice would be simple: send us all the information you can and let the experts take care of the rest. It may sound like a cliché, but with the right data, we can make your project work in the best possible way.