How IDEA’s AMR Solution Optimizes Transport and Reduces Labor Costs by 30% in Electronics Manufacturing

Overview

The client is a large corporation in the field of electronics component manufacturing, operating in a modern factory environment with high automation requirements. Due to the sharp increase in internal transportation volume, the client needed an AMR solution to optimize the transport flow, reduce labor costs, and improve production efficiency.

IDEA was tasked with providing an AMR solution to replace manual transport methods, fully automating the transportation of components from the raw material warehouse to the production line, while ensuring flexibility for future scalability.

Challenges

• Limited Factory Space: Although the factory is large, it is filled with machinery, creating narrow and complex pathways that require the AMR to have advanced navigation capabilities.
• High Precision Requirements: The AMR must deliver components to precise locations with an accuracy of no more than ±5mm.
• Safety and Compliance Standards: The solution must meet international safety standards, be able to avoid obstacles, and operate reliably in the busy factory environment.

Solution

IDEA implemented the AMR solution with the following key features:

• Advanced Navigation Technology:
  The AMR uses SLAM (Simultaneous Localization and Mapping) technology combined with LIDAR sensors and cameras to provide precise navigation even in tight and complex spaces.
• Custom Design:
  The AMR was designed to be compatible with the client’s existing trays and component containers, ensuring immediate usability without the need to modify the infrastructure.
• Automated Operating Process:
  The AMR is programmed with an optimized route to reduce transportation time. The entire process, from transportation requests to task completion, is fully automated.
• High Safety Standards:
  Integrated obstacle detection sensors and motion detection capabilities allow the AMR to automatically stop when encountering an obstacle and resume once the path is clear.

Implementation

• Survey and Planning:
  The IDEA team conducted a survey at the factory to analyze the transportation process and operational requirements.
• Installation and Testing:
  The AMR solution was deployed and tested in the actual environment to ensure accuracy and performance.
• Training and Handover:
  IDEA provided training for the client’s operations team on managing and maintaining the AMR solution.
• Monitoring and Optimization:
  After deployment, IDEA offered monitoring and optimization services to ensure the AMR operates at peak efficiency.

Results

• Improved Transportation Efficiency:
  The transportation time for components was reduced by 40%, enhancing the production line’s productivity.
• Labor Cost Reduction:
  The elimination of manual transportation workers resulted in over 30% reduction in labor costs.
• Increased Accuracy and Safety:
  The AMR transported components with an accuracy of ±3mm and no safety incidents during operation.
• Easy Scalability:
  The AMR system allows for easy addition of robots without changing the infrastructure, meeting future demands for increased transportation capacity.