Automobile Giant saved 75% in manpower with AGVs

Posted on 25th November 2016

This post is a case study involving AGV implementation at an automotive manufacturer firm based in India.

In India, this company is specialized in manufacturing passenger vehicles. Hatchbacks, Compact sedans, Sedans and SUVs.

Why are we introducing them?

The Case

They were looking for a solution for complex material feeding application. Kitting trolleys were to be supplied to different fast-moving assembly lines. To maintain JIT approach & reduce operator dependency, they decided to go for an automated material transfer solution.

Solution given

After studying the complete project, The Hi-Tech Robotic Systemz Ltd. proposed ‘Self-Driving Vehicles’ as a solution.

A Fleet of Tunneling Type Self-Driving Vehicles for Kit Fulfilment at 4 Assembly Lines were supplied. Integration of Vehicles’ CCU ( Central Control Unit ) was done with customer’s MES so as to automate dispatching/sequencing of vehicles and reducing human intervention for material movement to almost zero.

Features of System

  1. Automatic Hitching and Unhitching with Kitting Trolleys
  2. Opportunistic charging system for 24 hours operation
  3. Integration with customer MES for remote calling/dispatching of trolleys.


Automated Guided Vehicle in action

Outcomes from AGVs implementation

  1. Reduced Head-Count of Trolley moving reps by 75%
  2. ROI was realised within 26 months of operation
  3. Real-time monitoring of material was possible for all four lines.
  4. Enabled Customer to maintain JIT approach.
  5. Streamlined material flow ensures Zero bottlenecks on the floor.

Are you working with an automotive company? How are you managing your material movement challenges?

Topics:   Automated Guided Vehicles.