High-Payload Logistics Success! Lead Tab Automatic Transfer with OMRON AMR

Industry > Semiconductor·DisplayApplication > LogisticsSector > Logistics

#amr# Logistics# Omron# Heavy-duty conveying# Conveyor automation# Smart Logistics# Marosol

[Process Overview]

This case study features the automation of heavy product transport using OMRON AMR (Autonomous Mobile Robot) logistics robots. To reduce the inefficiency and physical strain caused by repetitive, heavy lifting, the client implemented an automated logistics system. The primary goal was to maximize logistics efficiency and reduce costs through automated palletizing and transport. By automating the movement and stacking of products, this solution increased dispatch accuracy and improved both worker safety and overall productivity.

[Project Background & Objective]

The client identified a critical need for automation in heavy cart handling and lead tab transport. By introducing AMRs, they aimed to streamline logistics operations and realize significant cost savings.

Automate lead tab transport and cart handling.

Enhance worker productivity and ensure operational safety.

Strengthen the efficiency and flexibility of the logistics site.

Components

Robot	OMRON AMR LD-90: Navigates autonomously while avoiding obstacles. Equipped with a dual-row conveyor, it can load and transport up to 6 lead tab trays.OMRON AMR LD-250: Equipped with a lift module to transport up to 64 lead tab trays via cart coupling. It automatically recognizes carts and moves autonomously to the destination.
Peripherals	Top Modules: Customizable attachments that automate repetitive tasks to boost productivity. Robot Station: A dedicated area for loading carts to be transported, supporting stable logistics flow.Combined Inspector: Inspects the trays delivered by the robot and automatically detects defects. Buffer Conveyor: Holds trays post-inspection, acting as a buffer to assist workers in loading carts. Tray Cart: Capable of holding up to 64 trays, designed for transport by the LD-250.

Robot

OMRON AMR LD-90: Navigates autonomously while avoiding obstacles. Equipped with a dual-row conveyor, it can load and transport up to 6 lead tab trays.OMRON AMR LD-250: Equipped with a lift module to transport up to 64 lead tab trays via cart coupling. It automatically recognizes carts and moves autonomously to the destination.

Peripherals

Top Modules: Customizable attachments that automate repetitive tasks to boost productivity.

Robot Station: A dedicated area for loading carts to be transported, supporting stable logistics flow.Combined Inspector: Inspects the trays delivered by the robot and automatically detects defects.

Buffer Conveyor: Holds trays post-inspection, acting as a buffer to assist workers in loading carts.

Tray Cart: Capable of holding up to 64 trays, designed for transport by the LD-250.

Workflow

STEP 1.	An operator clicks a button → The LD-90 receives the move command → The robot navigates autonomously to the designated location
STEP 2.	Trays are manually loaded onto the LD-90 conveyor → The robot transports them to the combined inspector
STEP 3.	The robot docks with the inspector → Trays are inspected → Post-inspection trays are loaded onto the buffer conveyor
STEP 4.	An operator manually transfers the trays from the buffer conveyor to the tray cart
STEP 5.	The LD-250 is called → It automatically recognizes the cart and transports it to the destination
STEP 6.	Upon completing the task, the robots automatically return to their standby locations

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Features

Solution Features

24-hour process response available Even in sites operating on a day and night shift system, robots can be charged alternately to enable uninterrupted Logistics transportation.
Bogie and AMR can be separated Fully loaded bogies can be stored at the station, allowing the AMR to perform additional tasks.
space-efficient system It is possible to share the workspace with the operator by utilizing various safety sensors mounted on the AMR, and the AMR can be stopped via the emergency stop button in emergency situations.
Easy operation A worker can call the robot by pressing a button installed on the production line or station without complex operations, and the robot automatically performs subsequent actions, making it easy for anyone to operate.

Introduction effect

Increased production efficiency Robots handle return operations, reducing the time production line workers spend away from the line and increasing production efficiency.
Cost reduction We reduced labor costs by automating the Logistics process, saving up to 8 personnel for day and night shifts.
Improved safety The autonomous driving function automatically avoids dangerous situations, and the emergency stop function minimizes the risk of accidents during operation.
Logistics tracking management optimization Through the real-time Logistics tracking system, we are now able to efficiently manage the status and location of product shipments.

Results

Key Benefits	This LeadTab AMR automated return solution demonstrated notable improvements in operational efficiency, safety, and workforce management. First, previously, 2 to 3 workers had to manually transport trays for each return process, but after the introduction of the automation solution, it became possible to operate with just one worker intermittently monitoring the robot, resulting in a labor cost reduction of over 50%. In addition, the efficiency of the production line was increased by reducing return work time by approximately 30% compared to the existing system, and the time workers spent away from the production line was reduced by more than 80%, creating an environment where they can focus on their core duties. Above all, work safety during the process of transporting heavy trays has been significantly improved. Thanks to the obstacle avoidance and emergency stop functions of the autonomous robot, there have been zero related accidents since its introduction.
Client Feedback	The client said, “The introduction of AMR robots has not only reduced the need for human workers but has also significantly improved Logistics safety. In particular, the well-equipped automation system has created an environment where workers can easily operate the robots and focus on their tasks.”

Key Benefits

This LeadTab AMR automated return solution demonstrated notable improvements in operational efficiency, safety, and workforce management. First, previously, 2 to 3 workers had to manually transport trays for each return process, but after the introduction of the automation solution, it became possible to operate with just one worker intermittently monitoring the robot, resulting in a labor cost reduction of over 50%. In addition, the efficiency of the production line was increased by reducing return work time by approximately 30% compared to the existing system, and the time workers spent away from the production line was reduced by more than 80%, creating an environment where they can focus on their core duties. Above all, work safety during the process of transporting heavy trays has been significantly improved. Thanks to the obstacle avoidance and emergency stop functions of the autonomous robot, there have been zero related accidents since its introduction.

Client Feedback

The client said, “The introduction of AMR robots has not only reduced the need for human workers but has also significantly improved Logistics safety. In particular, the well-equipped automation system has created an environment where workers can easily operate the robots and focus on their tasks.”