Process layout
Process Overview
This case study demonstrates the automation of heavy-duty product transport using Omron AMR logistics robots.
The client implemented a logistics automation system to reduce inefficiencies and labor burdens associated with repetitive, heavy logistics tasks. Specifically, they sought to reduce costs and maximize logistics efficiency through automated palletizing and return operations.
This solution automates simple, repetitive tasks like product movement and loading, thereby increasing the efficiency and accuracy of the shipping process and reducing worker burden, thereby enhancing safety and productivity.
Project Background and Objectives
The client recognized the need for automation in heavy cart transport and lead tab return operations and sought to improve logistics operational efficiency and reduce operating costs by introducing AMRs.
This project aimed to:
- Automating lead tab return and cart transport
- Improving worker productivity and ensuring safety
- Enhancing efficiency and flexibility in the logistics field
Components
| Robot | Omron AMR logistics robot LD-90: Moves autonomously while avoiding obstacles, equipped with a two-row conveyor, and loads and returns up to 6 lead tab trays. ; Omron AMR logistics robot LD-250: Equipped with a lift, transports up to 64 lead tab trays by combining with a cart, and moves autonomously to the destination after automatically recognizing the cart. |
|---|---|
| Peripherals | Robot upper module: Customization for tasks is possible, and productivity is increased by automatically processing repetitive tasks. ; Robot station: Loads the cart to be transported by the robot to support stable logistics return. ; Composite inspection machine: Inspects the trays returned by the robot, and automatically detects defective products. ; Buffer conveyor: Loads the trays after inspection, and provides a buffer to help workers load the cart. ; Tray cart: Up to 64 trays can be loaded, and is transported by LD-250. |
Workflow
| STEP 1. | Calling the operator: Click the button โ Receive command to move LD-90 โ Autonomous driving to the designated location |
|---|---|
| STEP 2. | Tray loading: Manually load trays onto the LD-90 conveyor โ Return to the composite inspection machine |
| STEP 3. | Inspection task: Inspector docking โ Tray inspection โ Buffer conveyor loading after inspection |
| STEP 4. | Cart loading: The worker manually loads the tray onto the cart. |
| STEP 5. | Cart transport: Call LD-250 โ Cart automatically recognized and transported |
| STEP 6. | End of work: The robot automatically returns to the waiting area after work. |
Features
Special Features
- 24-Hour Process Response: Even on sites with day-night shifts, robots can be alternately charged to ensure uninterrupted logistics transport.
- Separable Cart and AMR: Fully loaded carts can be stored at the station, allowing the AMR to perform additional tasks.
- Space-Efficient System: The AMR's various safety sensors allow for shared workspaces with workers, and an emergency stop button can be used to stop the AMR in an emergency.
- Easy Operation: Workers can call the robot by pressing a button installed on the production line or station, eliminating the need for complex operations. The robot then automatically performs the remaining operations, making it easy for anyone to operate.
Introduction Effects
- Increased Production Efficiency: Robots perform return tasks, reducing the time workers spend away from the production line and enhancing production efficiency.
- Cost Reduction: Automating logistics processes reduces labor costs by eliminating up to eight workers.
- Improved Safety: Autonomous driving automatically avoids hazardous situations, and emergency stop functions minimize the risk of accidents during operations.
- Optimized Logistics Tracking: A real-time logistics tracking system enables efficient management of product shipment status and location.
Results
| Key Benefits | This AMR automated lead tab return solution has demonstrated notable improvements in work efficiency, safety, and workforce management. Previously, each return process required two to three workers to manually transport trays. With the automated solution, operations can now be performed by just one worker, intermittently monitoring the robot, resulting in a labor savings of over 50%. Furthermore, return work time has been reduced by approximately 30%, improving production line efficiency. Furthermore, line outage time has been reduced by over 80%, allowing workers to focus on their core tasks. Most importantly, workplace safety has been significantly improved during the transport of heavy trays. Thanks to the autonomous robot's obstacle avoidance and emergency stop functions, zero accidents have occurred since its introduction. |
|---|---|
| Client Feedback | The client commented, "The introduction of AMR robots not only reduced worker input but also significantly improved logistics safety. In particular, the well-equipped automation system created an environment where workers could easily operate the robots and focus on their tasks." |
Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
Indoor Logistics Transport using VisionNav VNP15
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Plastic Injection Molded Part Transport using Twinny NarGo 100
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AI Palletizing using Hyundai YS140 and Mech-Mind
This automation solution utilizes Mech-Mind 3D Vision and the Hyundai YS140 industrial robot to automatically sort and stack boxes onto pallets by size, as well as transfer them to conveyors. By employing two sets of highly cost-effective 3D vision sensors, the system can stably perform both palletizing and depalletizing tasks even when various product boxes are mixed together (Mixed-Case Palletizing). The project was implemented to improve worker health and safety by automating tasks known to cause musculoskeletal disorders.
Process layout
Process Overview
This case study demonstrates the automation of heavy-duty product transport using Omron AMR logistics robots.
The client implemented a logistics automation system to reduce inefficiencies and labor burdens associated with repetitive, heavy logistics tasks. Specifically, they sought to reduce costs and maximize logistics efficiency through automated palletizing and return operations.
This solution automates simple, repetitive tasks like product movement and loading, thereby increasing the efficiency and accuracy of the shipping process and reducing worker burden, thereby enhancing safety and productivity.
Project Background and Objectives
The client recognized the need for automation in heavy cart transport and lead tab return operations and sought to improve logistics operational efficiency and reduce operating costs by introducing AMRs.
This project aimed to:
- Automating lead tab return and cart transport
- Improving worker productivity and ensuring safety
- Enhancing efficiency and flexibility in the logistics field
Components
| Robot | Omron AMR logistics robot LD-90: Moves autonomously while avoiding obstacles, equipped with a two-row conveyor, and loads and returns up to 6 lead tab trays. ; Omron AMR logistics robot LD-250: Equipped with a lift, transports up to 64 lead tab trays by combining with a cart, and moves autonomously to the destination after automatically recognizing the cart. |
|---|---|
| Peripherals | Robot upper module: Customization for tasks is possible, and productivity is increased by automatically processing repetitive tasks. ; Robot station: Loads the cart to be transported by the robot to support stable logistics return. ; Composite inspection machine: Inspects the trays returned by the robot, and automatically detects defective products. ; Buffer conveyor: Loads the trays after inspection, and provides a buffer to help workers load the cart. ; Tray cart: Up to 64 trays can be loaded, and is transported by LD-250. |
Workflow
| STEP 1. | Calling the operator: Click the button โ Receive command to move LD-90 โ Autonomous driving to the designated location |
|---|---|
| STEP 2. | Tray loading: Manually load trays onto the LD-90 conveyor โ Return to the composite inspection machine |
| STEP 3. | Inspection task: Inspector docking โ Tray inspection โ Buffer conveyor loading after inspection |
| STEP 4. | Cart loading: The worker manually loads the tray onto the cart. |
| STEP 5. | Cart transport: Call LD-250 โ Cart automatically recognized and transported |
| STEP 6. | End of work: The robot automatically returns to the waiting area after work. |
Features
Special Features
- 24-Hour Process Response: Even on sites with day-night shifts, robots can be alternately charged to ensure uninterrupted logistics transport.
- Separable Cart and AMR: Fully loaded carts can be stored at the station, allowing the AMR to perform additional tasks.
- Space-Efficient System: The AMR's various safety sensors allow for shared workspaces with workers, and an emergency stop button can be used to stop the AMR in an emergency.
- Easy Operation: Workers can call the robot by pressing a button installed on the production line or station, eliminating the need for complex operations. The robot then automatically performs the remaining operations, making it easy for anyone to operate.
Introduction Effects
- Increased Production Efficiency: Robots perform return tasks, reducing the time workers spend away from the production line and enhancing production efficiency.
- Cost Reduction: Automating logistics processes reduces labor costs by eliminating up to eight workers.
- Improved Safety: Autonomous driving automatically avoids hazardous situations, and emergency stop functions minimize the risk of accidents during operations.
- Optimized Logistics Tracking: A real-time logistics tracking system enables efficient management of product shipment status and location.
Results
| Key Benefits | This AMR automated lead tab return solution has demonstrated notable improvements in work efficiency, safety, and workforce management. Previously, each return process required two to three workers to manually transport trays. With the automated solution, operations can now be performed by just one worker, intermittently monitoring the robot, resulting in a labor savings of over 50%. Furthermore, return work time has been reduced by approximately 30%, improving production line efficiency. Furthermore, line outage time has been reduced by over 80%, allowing workers to focus on their core tasks. Most importantly, workplace safety has been significantly improved during the transport of heavy trays. Thanks to the autonomous robot's obstacle avoidance and emergency stop functions, zero accidents have occurred since its introduction. |
|---|---|
| Client Feedback | The client commented, "The introduction of AMR robots not only reduced worker input but also significantly improved logistics safety. In particular, the well-equipped automation system created an environment where workers could easily operate the robots and focus on their tasks." |
Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
Indoor Logistics Transport using VisionNav VNP15
Indoor Logistics Transport using VisionNav VNP15 This application case is an automated loading and unloading solution that utilizes VisionNav's VNP15 to automate the process of transporting and stacking packed products. Based on strict safety features, it minimizes changes to existing processes, enables unmanned loading/unloading tasks, and allows for effective monitoring and control of the work status.
Plastic Injection Molded Part Transport using Twinny NarGo 100
This logistics automation solution utilizes the Twinny NarGo 100 AMR to automate the transport of large plastic injection molded products to subsequent process stages. Equipped with triple safety sensors and advanced autonomous driving technology, Twinny's NarGo 100 performs tasks safely even in factories with complex layouts and high worker traffic. Previously, transporting heavy workpieces weighing around 100kg to a distant finished goods warehouse was time-consuming, causing idle time in processing and reducing productivity due to worker fatigue. Since implementing the autonomous robot, continuous processing has become possible, and worker fatigue has been significantly reduced, leading to an overall boost in productivity.
AI Palletizing using Hyundai YS140 and Mech-Mind
This automation solution utilizes Mech-Mind 3D Vision and the Hyundai YS140 industrial robot to automatically sort and stack boxes onto pallets by size, as well as transfer them to conveyors. By employing two sets of highly cost-effective 3D vision sensors, the system can stably perform both palletizing and depalletizing tasks even when various product boxes are mixed together (Mixed-Case Palletizing). The project was implemented to improve worker health and safety by automating tasks known to cause musculoskeletal disorders.