Case Study | Autonomous Vehicle Solution For Smart Factory

A leading FMCG (Fast-Moving Consumer Goods) manufacturer in Japan sought to automate pallet transportation within their factory, replacing traditional manual forklift systems. Their objectives included reducing labor costs, optimizing transportation flow, and enhancing workplace safety. IDEA Technology was selected to provide an Autonomous Vehicle Solution with a maximum load capacity of 1 ton, ensuring seamless integration with the existing production management system.

Challenges

• Handling Heavy Loads
  The autonomous vehicle needed to transport 1-ton pallets over long distances within the factory while maintaining high stability.
• Minimizing Disruptions to Production
  Since the system was deployed in an active production environment, careful planning and coordination were required to avoid disruptions.
• Ensuring Safety & Precision
  The autonomous vehicle needed to operate safely in high-traffic areas, avoid collisions, and comply with international safety standards.

Solution

IDEA Technology developed and implemented an Autonomous Vehicle Solution for pallet transportation, featuring the following:

• Advanced Navigation Technology
  • Utilizes SLAM (Simultaneous Localization and Mapping) with LIDAR sensors and cameras for intelligent navigation.
  • The autonomous vehicle can navigate narrow aisles and avoid obstacles automatically.
• Customized Design for Load Capacity
  • Equipped with a hydraulic lifting system, capable of safely lifting and transporting 1-ton pallets.
• Enhanced Safety Features
  • Integrated obstacle detection sensors, warning lights, alarms, and emergency stop functions.
  • The vehicle automatically slows down in blind spots and high-traffic areas.
• Automated Charging System
  • When battery levels are low, the vehicle autonomously returns to the charging station, enabling continuous operation without manual intervention.

Implementation Process

• Analysis & Planning
  • Conducted a detailed survey of factory layout and transportation flow to design the optimal autonomous vehicle routes.
• Manufacturing & Deployment
  • The autonomous vehicles were manufactured, equipped with navigation software, and tested in a controlled environment before deployment.
• Training & Handover
  • Conducted training sessions for operators on vehicle usage, management, and maintenance.
• Performance Monitoring & Optimization
  • Monitored vehicle performance for the first two weeks and optimized routes based on real-time operational data.

Results

• Improved Transportation Efficiency
  • 35% increase in pallet transportation efficiency, reducing production downtime.
• Reduced Operational Costs
  • 25% reduction in labor costs compared to traditional forklift operations.
• Enhanced Workplace Safety
  • Eliminated forklift-related collisions, creating a safer working environment.
• Eco-Friendly Operations
  • Lithium-ion battery-powered vehicles reduced emissions compared to internal combustion forklifts.