AMR Solution for an Electronics Component Manufacturing Plant

Project Overview

The client, a major electronics component manufacturer operating in a modern factory with high automation demands, faced challenges due to increasing internal transportation volumes. They required a solution to optimize transport flows, reduce labor costs, and enhance production efficiency.

IDEA was tasked with delivering an AMR solution to:

• Replace manual transportation methods.
• Fully automate the transport of components from the raw material warehouse to production lines.
• Ensure flexibility and scalability for future needs.

Challenges 

1. Limited factory space:
   • The large-scale factory featured numerous machines, creating narrow and complex pathways requiring AMRs with advanced navigation capabilities.
2. High precision requirements:
   • AMR solution needed to deliver components with an accuracy of ±5mm to designated production line locations.
3. Safety and compliance:
   • The solution had to meet international safety standards, including obstacle avoidance and stable operation in crowded factory environments.

Solution

IDEA implemented an AMR system with the following key features:

1. Advanced navigation technology:
   • The AMRs utilized SLAM (Simultaneous Localization and Mapping) technology, leveraging LIDAR sensors and cameras for precise navigation and environment recognition, even in narrow spaces.
2. Custom design:
   • AMRs were tailored to accommodate the client’s existing trays and component containers, ensuring compatibility without requiring infrastructure changes.
3. Automated operation workflow:
   • Optimized route programming minimized transportation times.
   • Automated workflows covered the entire process, from receiving transport requests to confirming task completion.
4. Enhanced safety features:
   • Integrated obstacle and personnel detection sensors ensured safe operation.
   • The AMRs automatically stopped when encountering obstructions and resumed operation once the path was clear.

Implementation

1. Survey and planning:
   • The IDEA team conducted a thorough survey of the factory layout, analyzing workflow and transport requirements.
   • This helped design optimal routes for the AMRs, ensuring maximum efficiency and minimal disruption to production.
2. Installation and testing:
   • AMRs were deployed and rigorously tested under real-world conditions to verify their performance.
   • The testing phase ensured the solution met all accuracy and operational requirements before full-scale deployment.
3. Installation and testing:
   • AMR solution was deployed and rigorously tested in real-world conditions to ensure accuracy and performance.
4. Training and handover:
   • IDEA provided comprehensive training to the client’s team, covering both system operation and maintenance.
   • This ensured a smooth handover, allowing the client to manage the AMR solution effectively moving forward.

Results

1. Increased transport efficiency:
   • Component transport times were reduced by 40%, significantly boosting production line productivity.
2. Reduced labor costs:
   • Eliminated the need for human resources in internal transport tasks, achieving over 30% savings in labor costs.
3. Improved accuracy and safety:
   • AMRs delivered components with an accuracy of ±3mm, and no safety incidents occurred during operation.
4. Easy scalability:
   • The client could effortlessly add more AMRs to the system as transport demands grew, without altering the existing infrastructure.

Clients Feedback

The client highly valued IDEA’s solution for its flexibility, precision, and rapid deployment. Following the success of this project, they decided to expand their partnership with IDEA Group to deploy additional AMR solution at other factories in the region.

The Autonumous vehicle solution successfully optimized material flow, reducing reliance on manual labor. Contact us today to explore how IDEA can enhance your production efficiency with automation solutions.