For the team at SmartCap, building top-notch gear for outdoor adventurers isn’t just a business — it’s a passion driven by their own love for the wild. But as demand for their rugged, modular truck caps soared after their move to North America in 2022, they hit a snag: How do you ramp up production without sacrificing the meticulous quality you are known for, all while navigating a tough labor market? Their answer? A bold step into the world of intelligent automation, teaming up with GrayMatter Robotics, and employing the company’s innovative Scan&Sand™ system.
Since 2007, SmartCap has carved a niche for themselves, evolving from a small fabrication outfit in South Africa to a key player in the outdoor lifestyle scene. Their stateside expansion was a game-changer, opening up new opportunities. Yet, as CEO and Founder Michael Voss pointed out, it also brought a new set of realities. “Labor in North America comes at a premium,” he explained, “and to really compete and build our products here, we knew automation wasn’t just a plus — it was essential.” Adding to this, General Manager Jan Strydom emphasized the practical challenges, “Finding enough hands for the job in this market is a real hurdle. Automation became the clear path to keep up with demand.”
Beyond numbers, there was the gritty reality of the manual sanding process. Getting the flawless finish SmartCap’s customers expect demanded a skilled touch. “Blending those welds so they disappear into the original form? That’s a craft,” Voss said, “and it’s tough to get that perfect consistency every single time.” Plus, let’s be honest, grinding metal isn’t anyone’s idea of a good time — it’s messy, tiring, and takes a toll on the body.
SmartCap had dipped their toes into automation before and it wasn’t always a smooth sail. As Strydom recalled, “Programming robots the old way can eat up a lot of time, and it doesn’t give you much wiggle room.” They needed something smarter, something more adaptable to the nuances of their products.
Their search for a better way led them to GrayMatter Robotics and their Scan&Sand™ system, a clever blend of AI-powered vision and robotic precision. For Voss, it was almost a moment of discovery. “We were literally online, typing in things like ‘scan and sand’ — and GrayMatter [Robotics] popped right up. What they showed us? It was like a light bulb went off.”
The magic of Scan&Sand™ lies in its ability to “see” each part. It scans the surface, pinpointing exactly where the sanding needs to happen — typically along those weld lines. Then, the robot gets to work, applying just the right amount of pressure, guided by pre-set instructions. This means no wasted effort and a consistently smooth finish, part after part.
“What really grabbed us was the scanning tech,” Strydom said. “Other systems we looked at? They were all about manual programming. GrayMatter Robotics’ approach, where the robot basically ‘sees’ what needs to be done? That’s a whole different ballgame.” It gave SmartCap the flexibility they were looking for, a system that could adapt to their designs without endless lines of code.
The arrival and setup of the Scan&Sand™ system was surprisingly quick. “We’re talking weeks, not months, from initial talks to having the robot up and running,” Strydom highlighted. And the impact? It’s been nothing short of remarkable:
Production Skyrockets: SmartCap is now churning out 50 percent more of their high-quality caps with the same team — a huge leap in efficiency.
Quality Control Gets a Robotic Ally: The consistent precision of the robot means a flawless finish every time. As Voss put it, “We want every customer to have that same ‘wow’ experience, and the robot helps us nail that consistency.”
Less Strain on Shoulders (and the Budget): Automating the sanding has eased the physical demands on their team and brought down labor costs. For Monique Williams, the lead machine operator, the difference is night and day. “This robot has changed my life,” she said. “I actually have energy to spend time with my grandkids after work now, instead of just being worn out.”
Scaling Made Simple: Need to boost production even more? Adding another Scan&Sand™ unit is a straightforward process, giving SmartCap the agility to grow. “This solution has opened up a whole new level of scalability for us,” Strydom said.
Support That Never Sleeps: GrayMatter Robotics’s commitment to around-the-clock support means minimal hiccups in production. “Their support is just amazing,” Williams raved. “Anytime we have a question, they’re right there to help, day or night.”
Predictable Costs, Predictable Growth: The subscription model offered by GrayMatter provides SmartCap with a clear and manageable monthly expense. “It just made sense for us,” Voss said. “Knowing our costs upfront helps us plan for the future with confidence.”
For SmartCap, embracing AI-powered robotics isn’t just about keeping up; it’s about setting the pace. They have not only tackled their immediate challenges but also created a more sustainable, efficient, and employee-friendly manufacturing environment.
“This technology isn’t just a tool; it’s the future of making things, especially here in the USA,” said Voss. “What we’ve achieved with GrayMatter [Robotics] is proof of that, and we’re excited to see where this journey takes us next.” SmartCap’s story is a powerful reminder that when human ingenuity teams up with intelligent automation, the possibilities for growth and innovation are truly limitless.
This article was provided by GrayMatter Robotics (Carson, CA). For more information, visit here .
