Overview
Kohler’s Casa Grande facility is a next-generation smart factory showcasing large-scale automation, real-time digital connectivity and advanced manufacturing at enterprise scale. Opened in 2024, this more than one-million-square-foot operation is the largest and most highly automated investment in Kohler’s 150+ year history.
The plant produces bathtubs, showers, and wall sets through an end-to-end automated process—from sheet molding compound fabrication to robotic molding, trimming, packing, palletizing, and automated warehouse integration. AI-enabled process monitoring and fully connected systems drive precision, quality, and continuous optimization across the factory.
While automation is foundational, people remain central to performance. Kohler’s offline training dojo ensures employees are trained, certified, and confident before entering production, enabling safe, efficient operations in a highly automated environment. The Casa Grande facility is located just outside the Phoenix metropolitan area.
Walk Away with Actionable Insights
Key Takeaways:
Real-Time Process Monitoring and AI-Enabled Control
AI-driven software synchronizes material fabrication with downstream molding operations, monitoring and tracking critical process parameters to support Six Sigma capability and consistent quality outcomes.
Advanced Automation at Scale
Extensive use of robotics across production, material handling, and packaging showcases how large-scale automation can drive throughput, repeatability, and cost efficiency.
People-Centered Smart Manufacturing
Despite high automation, workforce readiness is a priority. The offline training dojo equips employees with the skills and certifications needed to operate confidently in a digitally enabled environment.
AGVs and Intelligent Warehouse Operations
Automatic Guided Vehicles (AGVs) support material movement throughout the facility, while integrated warehouse management software optimizes task generation and execution for high-efficiency logistics.
Safety, Quality and Operational Excellence
Kohler’s integrated focus on people, systems, and processes delivers safe operations, exceptional product quality, and a superior customer experience.
