Automated logistics in the Incoming Logistics department of a leading car manufacturer

Logistics processes in the automotive industry are facing major challenges: The shortage of skilled workers, increasing competitive demands and the need to reduce costs are driving companies to further optimize their processes. A renowned company from this industry has decided to work with 4am Robotics to sustainably increase efficiency in incoming goods through automated solutions.

Goal: Automation of manual processes

The project focuses on the gradual automation of the previously manual incoming goods processes - from unloading and storage to transportation to the construction site. The strategy envisages relieving employees of repetitive tasks and concentrating their skills on critical activities that cannot be automated.

Analyse the processes: Identifying automation potential

At the beginning of the project, all process steps in incoming goods were examined for their automation potential. This showed that the transfer between the incoming goods department (GR) and the interim warehouse was particularly promising:

• Short travel distances: Ideal for automated transportation.
• Repeatable sales movements: Standardized processes for high efficiency.
• KLT handling: The transportation of small load carriers (KLTs) offers great potential for automation.
  
  

Challenges: Irregular pallet structures and conditions

One of the biggest challenges was the structure of the delivered pallet stacks. Although the KLT boxes on the pallets are the same size, they are stacked at different heights. This made it impossible to use conventional automation solutions with predefined size parameters.

A camera-based perception approach was the key technology for overcoming this challenge. This uses sensors and camera systems that record the height and structure of the pallets in real time and enable precise handling.

In addition, the analysis of pallet quality revealed further difficulties:

• Pallet condition: Only around 10-15% of Euro pallets in circulation are in perfect condition for reliable automated handling.
• Interfering factors: Paper and film residues on the pallets make machine recognition difficult.
• Lighting conditions: Fluctuating light in the storage area placed additional demands on the camera systems.

Thanks to the autonomous AFI-M forklift trucks, based on the Linde L16AC, these challenges were successfully overcome.

Optimized navigation: precision in confined spaces

Another challenge was the navigation of several forklifts in confined areas in front of the interim storage facility. The movement of the AMRs in overlapping safety and movement zones required an advanced navigation solution. Unlike conventional systems, which plan robots as a point rather than an ASL outline, outline control was introduced for this project. This enabled smooth coordination in confined spaces.

Results: Efficient processes and satisfied employees

The introduction of autonomous forklift trucks has brought tangible benefits for the customer:

• Improved process stability: The standardized and automated transfer from incoming goods to interim storage minimizes fluctuations in the material flow. This ensures greater planning reliability and reduces downtimes in the production process.
• Optimized personnel utilization: Counteracting the shortage of skilled workers and relieving the burden on employees, who can now concentrate on more value-adding tasks.
• Future-proof processes: We are currently working on an expansion project to adapt the control system in order to achieve even higher throughputs per dispensing station. Two robots will supply the same station in quick succession.
  

Conclusion

With the successful implementation of autonomous forklifts, our customer was not only able to increase the efficiency of logistics processes, but also strategically future-proof incoming goods. The combination of innovative camera technology, precise navigation and a flexible approach shows how automation can boost both competitiveness and employee satisfaction in the automotive industry.

Would you like to find out more about our PL d-certified AMRs or are you thinking about how you can make your logistics processes safer and more efficient? Visit our product page or do not hesitate to contact us.

Together we will find the optimum solution for your company!

Automation in action: how our autonomous forklifts work

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