AGV Solution Using Magnetic Line to Tow Carts for an Export Leather Shoe Manufacturing Plant

Project Introduction

The client is a large-scale export leather shoe manufacturing plant that primarily supplies the U.S. and European markets. With over 1,000 employees, the factory faces challenges in managing material and product flow between areas, which mainly relies on manual labor.
IDEA was tasked with providing an AGV solution using magnetic lines to tow carts, aiming to:

1. Reduce dependency on manual labor for internal transportation.
2. Automate material flow from the warehouse to production lines and finished goods transportation to the shipping warehouse.
3. Increase efficiency and reduce operational costs.

 Challenges

1. Complex transportation flow
   • The plant has multiple production areas requiring AGVs to navigate narrow paths and numerous intersections flexibly.
2. High and continuous load requirements
   • Carts carrying raw materials and finished goods weigh 300–500 kg and need to be transported continuously across three production shifts daily.
3. Efficiency optimization without disrupting production
   • The solution needed to be implemented swiftly without interrupting factory operations.
4. Safety and compatibility
   • AGVs must operate safely in a high-density workforce environment and be compatible with existing carts.

Solution

IDEA designed and implemented an AGV system tailored to the leather shoe manufacturing plant:

1. Magnetic line navigation system:
   • Magnetic lines affixed to the floor provide a fixed route for AGVs. The lines are designed to match the factory layout and can be easily adjusted when needed.
2. Custom-designed AGV:
   • The AGV is equipped with a custom towing mechanism compatible with existing carts, ensuring efficient operation and cost savings.
3. Advanced safety sensors:
   • AGVs are fitted with LIDAR and ultrasonic sensors to detect obstacles, slow down, or stop when encountering people or objects on their route.
4. High-performance battery:
   • Lithium-ion batteries with fast-charging capabilities allow the AGVs to operate continuously for 8–10 hours, meeting the demands of three shifts per day.

Implementation

1. Survey and planning
   • Conducted a factory layout survey and analyzed material and product flow to design optimal routes.
2. Installation and testing
   • Installed magnetic lines along key factory routes.
   • Deployed and tested AGVs on these routes to ensure stable operation.
3. Training and technology transfer
   • Trained the client’s management and operational teams on AGV coordination, troubleshooting, and routine maintenance.
4. Monitoring and optimization
   • Monitored AGV system performance during the first month and adjusted routes and schedules for maximum efficiency.

Results

1. Improved transportation efficiency
   • Reduced material transportation time by 35%, enabling uninterrupted and more efficient production line operations.
2. Lower labor costs:
   • Saved 20% on labor costs by eliminating manual transportation tasks.
3. Enhanced workplace safety
   • No incidents of collisions or injuries occurred with our AGV solution.
4. Scalability:
   • The magnetic line system can be easily expanded to accommodate additional AGVs or process changes.
5. Customer satisfaction
   • The client praised the solution’s stability, ease of use, and flexible integration capabilities provided by IDEA.

The AGV 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.