Manufacturers everywhere are under pressure: customer demand shifts rapidly, skilled labor is harder to find, and downtime is more costly than ever. For shops running CNC lathes, the difference between profit and loss often comes down to one factor — spindle uptime. Every second a spindle sits idle due to manual loading or inefficient handoffs is lost revenue.

Integrated gantry automation changes that equation. By automatically loading, unloading, and transferring parts directly within CNC lathes, it keeps your spindles cutting, reduces reliance on scarce labor, and makes throughput more predictable.

Learn more about how integrated automation works in this video featuring the Muratec MSR60.

What is Integrated Gantry Automation?

Integrated gantry automation refers to CNC lathes equipped with built-in gantry loaders. Instead of waiting for an operator to load the next blank or remove a finished part, the gantry handles these tasks. Mounted on top of the machine, the gantry moves parts quickly and precisely from input trays to spindles, then to finished-part collections or even other machines.

The key difference with this type of automation is that it is designed into the machine itself — not bolted on later. It’s seamless, reliable, and optimized for turning operations.

“Implementing this type of integrated automation into a shop can revolutionize a company’s way of doing business,” said Jeff Kalmbach, general manager of Muratec USA’s Machine Tools Division. “While many manufacturers have just started to offer gantry-loaded systems to the market, Muratec USA has been pioneering this approach to automation for decades.  Rather than just beginning to add this feature to machines, Muratec USA is continuing to find ways to improve on the critical areas of operation that contribute to spindles not turning: idle times, load/unload times, and wasted motions.”

The Common Shop Floor Problems Integrated Gantry Automation Solves

Let’s look at some of the most pressing problems manufacturers face today — and how integrated gantry automation addresses them.

1. Labor Shortages and Operator Fatigue

Skilled operators are increasingly difficult to hire and retain. Even when staffed, an operator’s repetitive loading and unloading tasks can cause fatigue and lead to errors. This not only slows production but also increases labor costs per part and generates waste.

2. High-Mix, Low-Volume Complexity

Shorter runs and frequent changeovers are now the norm. Each job requires handling adjustments, setup, and reorientation, which translates to lost spindle time and wasted labor on non-value-added activities.

3. Multi-Process Bottlenecks

Many parts require multiple operations on different lathes. Manually transferring and storing work-in-process between machines increases delays, risk of part damage or misplacement, and use of valuable floorspace, and creates scheduling headaches.

4. Handling Larger or Heavy Parts

When parts are heavy or oversized, manual handling becomes a safety risk. It also slows cycle times and introduces variability that affects both quality and throughput.

5. Order Surges and Missed Deadlines

Shops often find themselves scrambling when a customer unexpectedly increases order volumes. Manual loading and unloading slow the pace, leaving machines idle when they should be cutting. Meeting delivery schedules becomes nearly impossible without overtime or additional staff.

The Measurable Benefits of Integrated Gantry Automation

By addressing these problems, integrated gantry automation provides manufacturers with clear, measurable improvements:

• Increased spindle uptime — Machines cut more hours per day because they’re not waiting on manual handling and extended idle times. Lights-out manufacturing becomes possible with integrated automation, enabling shops to run a second shift unmanned to add to production capacity.
• Lower labor costs per part — Operators oversee multiple machines instead of being tied to one.
• Improved consistency — Automated handling ensures repeatable cycle times and quality.
• Faster throughput — Eliminating handoffs and manual transfers shortens total lead time.
• Scalability — Adding machines with integrated gantries expands capacity without linear increases in labor.
• Minimize Waste – Reduce floorspace and footprint: work in process can be reduced, fencing and cages are reduced, freeing up space for additional equipment (or for all the extra parts you’re making!).
• Reduced Injury/Fatigue – The gantry is doing the work; repetitive motion injuries are reduced.
• Employee Morale and Retention – Automation won’t replace humans—it will augment[CW1]  them. Operators will focus more on overseeing complex processes, analyzing data, and solving problems, while machines handle repetitive tasks. This shift creates opportunities for employees to upskill in technology, process optimization, and system management.

Manual Handling vs. Robotic Arms vs. Integrated Gantry Automation

Manufacturers have several options for managing part loading and unloading on CNC lathes. Each approach has its place, but understanding the differences in efficiency, reliability, and scalability is crucial.

Approach	How It Works	Advantages	Limitations	Best Fit
Manual Handling	Operators load blanks into the machine and wait for the cutting cycle to complete. Unload finished parts after cutting cycle. Manually open the door, manual blow off and clearing of the cutting area for the next part.	Low initial cost. Flexible for small volumes.	High labor cost per part, inconsistent cycle times, low productivity, low spindle utilization, safety risks with heavy parts, risk of repetitive motion injuries, limited scalability.	Very low-volume job shops or prototyping.
Add-On Robot or Gantry	A robot or secondary gantry loads blanks into the machine and waits for the cutting cycle to complete. Unload finished parts after the cutting cycle is complete. Opening the door, blowoff and cleaning may be incorporated into the cycle.	Reduces operator strain and repetitive motion injuries, allows for unattended operation. Offers some flexibility with various part shapes.	Additional floor space to install the robot, inefficiencies due to idle times like door open/close and part exchanges, third party software and control integrations.	Heavy parts, mid-volume production shops.
Integrated Gantry Automation	A built-in gantry loader travels above the machine, loading blank parts and unloading finished parts after the cutting cycle. Additional automation and handling while the machine is cutting, like maasurement stations, cleaning, part making or transfers to another machine.	Ultimate in spindle uptime, reduces operator strain and repetitive motion injuries. Reduced floor space, high productivity and efficiency, flexible operation choices, connectivity to subsequent machines, integrated software and controls (not added on after the fact).	Higher upfront investment, gantry weight capacities may be limited.	Production shops, low/mid/high volume, high mix with changeovers, product family production, multiple machine cells, shops looking to enter automation and maximize spindle uptime.

Bottom line: While manual handling and standalone robots can help in certain scenarios, integrated gantry automation is the most efficient and scalable choice for CNC lathe production. Integrated gantry automation has been designed specifically to keep spindles cutting, not waiting, and eliminates many of the bottlenecks that hold shops back.

Muratec CNC Lathes with Integrated Gantry Automation

While others in the industry are just now “jumping on board” with gantry-equipped lathes, Muratec USA has been refining this approach for decades, Kalmbach said.

“Our machines are designed as complete systems, with automation built in from the ground up…from the BEGINNING. That’s why shops around the world trust Muratec USA to keep spindles cutting and orders moving,” he said.

Here’s a closer look at our models:

• MW120/MW200 – Compact and powerful twin-spindle CNC lathes designed for high-volume or high-mix production. With its integrated gantry, it can load raw blanks and unload finished parts quickly and efficiently, keeping cycle times extremely short and predictabl

• MWR120 – A twin-spindle CNC lathe with integrated gantry system to move workpieces seamlessly between machines and spindles.  This multi-tasking machine with live tooling and Y-axis milling functionality is perfect for shops that need continuous flow when producing complex shaped parts.
  
• MW400 – A solution designed for larger workpieces utilizing its massive integrated gantry system for part handling. This integrated gantry manages heavy or oversized parts safely and consistently, eliminating manual lifting and reducing operator risk.

Designed to handle heavy parts, the MW400 is the largest machine in Muratec USA’s lineup of CNC lathes.

Each of these machines combines world-class Japanese engineering with Muratec’s legacy of automation expertise at their core. They’re not just CNC lathes — they’re productivity systems built to handle modern manufacturing challenges.

Getting Started with Gantry Automation

If you’re considering integrated gantry automation for your shop, here’s a simple roadmap:

1. Identify your bottlenecks — Where is spindle idle time occurring? Manual loading, short runs, transfers, or heavy parts?
2. Define your goals — Higher throughput, lower labor costs, reduced footprint, improved quality, employee morale, safer handling, or all of the above?
3. Select the right system — Choose a Muratec CNC lathe model that fits your production mix and part size.
4. Pilot and measure — Implement automation in one cell, track spindle utilization, and calculate labor savings.
5. Expand confidently — Once ROI is proven, scale with additional machines and connected cells.

“The automation experts at Muratec USA know exactly how to provide you the information you need, whether you are taking your first step towards automating or you have been automating all along,” Kalmbach said. “With hundreds of years of experience among them, our team knows automation, that’s what we do day-in and day-out.  Trust the BEST in your automation journey.”

Conclusion: Proven Leadership in Integrated Gantry Automation

For CNC lathe users, integrated gantry automation offers a clear, proven path to higher efficiency. By solving problems like labor shortages, order surges, and multi-process bottlenecks, it allows manufacturers to keep spindles cutting and deliver more parts with fewer resources.

The built-in gantry automation of the MWR120 is available with a choice of single or dual gantries, depending on processing needs.

Muratec has been a pioneer in this field for decades, delivering machines like the workhorse MW200 and MW120 while introducing new technology like the MWR120 and MSR60 – all built with automation at their core.

“While others are just starting to follow this automation trend, Muratec USA remains the leader — helping manufacturers around the world meet today’s toughest challenges with reliable, fully integrated solutions,” Kalmbach said.  “Trust in the BEST.  Automation is in our DNA.”