The client is a large factory manufacturing leather shoes for export to the American and European markets, employing over 1,000 workers. The factory was struggling with managing the flow of raw materials and finished products between various areas, relying heavily on manual labor.
IDEA was chosen to provide an AGV solution using magnetic guidance lines to pull trolleys, aiming to:
- Reduce reliance on labor for internal transportation tasks.
- Automate the flow of raw materials from the warehouse to the production line and finished goods to the shipping warehouse.
- Improve productivity and reduce operational costs.
Challenges
- Complex Transportation Flow
The factory has multiple production areas, and the AGV needs to move flexibly through narrow passages and many branches.
- Heavy Loads and Continuous Operation
Trolleys carrying 300–500kg of raw materials or finished products need to be transported continuously across three shifts daily.
- Optimizing Efficiency Without Affecting Production
The solution must be deployed quickly without disrupting the factory’s ongoing operations.
- Safety and Compatibility
The AGV must operate safely in a high-density labor environment and be compatible with the existing trolleys.
Solution
IDEA designed and implemented an AGV solution for the leather shoe manufacturing factory with the following features:
- Magnetic Line Guidance System
A magnetic line fixed to the floor was used to create fixed routes for the AGVs. The magnetic lines were designed to fit the factory layout and can be easily adjusted as needed.
- Customized AGV Design
The AGVs were designed with appropriate towing hook systems to connect with existing trolleys, ensuring efficiency and cost savings.
- Advanced Safety Sensors
The AGVs are equipped with LIDAR and ultrasonic sensors to detect obstacles, slow down, or stop when people or objects are in the way.
- High-Performance Battery
The AGVs use lithium-ion batteries with fast charging capabilities, allowing continuous operation for 8–10 hours, meeting the 3-shift daily operation requirement.
- Operational Management System
Integrated management software to coordinate multiple AGVs, ensuring synchronized operations and continuous transportation flow.
Implementation Process
- Survey and Planning
IDEA conducted a thorough analysis of the factory layout and raw materials/finished goods transportation flow to design the optimal AGV routes.
- Installation and Testing
Magnetic lines were installed along the primary routes in the factory. AGVs were then installed and tested on these routes to ensure stable operation.
- Training and Handover
Training sessions were conducted for the client’s management and operations teams, covering AGV adjustment, troubleshooting, and regular maintenance procedures.
- Monitoring and Optimization
The AGV system’s performance was monitored during the first month, and routes and schedules were adjusted to optimize efficiency.
Results
- Improved Transportation Efficiency
The transportation time for raw materials was reduced by 35%, allowing the production line to operate continuously and efficiently.
- Reduced Labor Costs
Manual transportation tasks were eliminated, resulting in a 20% reduction in labor costs.
- Enhanced Workplace Safety
There were no collisions, accidents, or injuries during AGV operation.
- Ease of Expansion
The magnetic line system is easily expandable, allowing the factory to add more AGVs or modify production processes in the future.
- Customer Satisfaction
The customer highly appreciated the stability, ease of use, and flexible integration of IDEA’s AGV solution.
