The automotive manufacturing industry is facing numerous challenges, with constant technological innovations demanding quick adaptation. Manufacturers grapple with questions of what to do and where to start, amidst a rapidly evolving technological landscape. How to keep up with these trends to streamline processes, enhance production efficiency, and ensure worker safety?
Rozitek, a leading technology solutions provider, introduces an automation solution using Autonomous Mobile Robots (AMR) to optimize the manufacturing process for an automotive plant in this article.
Challenge: How to make it more and more efficiency?
Changan Automobile is one of the 4 largest car manufacturing groups in China. They have 161 years of formation and 39 years in the field of car manufacturing. Changan has 9 production areas and 27 large factories worldwide. As a representative of Chinese car brands, Changan Automobile owns independent brands such as Changan Qiyuan, Deep Blue Automobile, Avita Technology, Changan Gravity, Changan Kai Cheng as well as joint venture brands such as Changan Ford, Changan Mazda, and Jiangling.
The car industry has developed rapidly and entered the “customized production” phase, producing according to customer requirements. The variety of car types has led to an increase in the number of raw materials, making it more difficult to manage product codes and suppliers.
Therefore, in recent years, with a surge in orders, Changan has constantly been looking for solutions to manage a huge amount of raw materials without affecting the production capacity of the business.
Breakthrough Automation Solution: Replace traditional conveyors with Autonomous Mobile Robots (AMR)
At the logistics center of Nanjing Changan Automobile Co., Ltd., the factory has decided to build an intralogistics system to transport goods within the factory, using more than 400 AMR robots, including Flash underriding robots; Heavy-duty HULK robots; Towing robots, and BEAST stacking robots. To see detailed information about Rozitek’s AMR products, please refer to:
These AMR robots have the task of :
- Transporting car bodies through processes such as stamping parts, welding parts, assembling interiors, manufacturing batteries, installing batteries, installing front and rear axles, painting car bodies, etc.
- Transporting tools, and materials from the warehouse to the installation position
- Transporting finished cars to storage warehouses,
- Automatic picking, and shipping at smart warehouses
With this solution, the AMR system has performed many tasks, completely changing the car production line of Changan.
THE AUTOMOTIVE PRODUCTION LINE TAKES AUTONOMOUS ROBOTS AMR AS THE MAIN INTRALOGICTICS CENTER:
The final interior installation and assembly process, using traditional conveyor belts, has been replaced by customized heavy-duty AMR robots for the factory. The large-capacity HULK AMR can lift and transport an entire car. The movement of the car body and the movement of materials at the same time are synchronized under the management of RCS. This will help: when the car body arrives, the material also arrives, ensuring the production of the right product, at the right time, in the right process, flexibly changing different materials and shapes.
FULLY AUTOMATE THE STAMPING PROCESS
Thanks to the use of a unified, connected, and communicative system, including AMR robots, barcode-reading cameras, stamping machines, cutting machines, peripheral devices, device management software, etc. The process of cutting and stamping car parts takes place completely automatically.
AUTOMATICALLY PICK UP AND MANAGE SMALL-SIZED MATERIALS IN THE SMART 3D WAREHOUSE
In the smart warehouse, the BEAST robotic warehouse management system demonstrates its intelligence and agility, combined with 3D cameras, barcode-reading machines, and FLASH autonomous robots to pick up and automatically manage product codes for very small car parts.
Rozitek’s smart warehouse system has proven its ability through many successful projects. To refer to a comprehensive solution, please visit:
DIGITALIZE INFORMATION MANAGEMENT PROCESS
The intelligent warehouse management system iWMS and the robot control system RCS are seamlessly connected to the LMS system to manage digital information about the warehouse and material distribution for the production line; RCS is connected to PLC processing devices to interactively exchange information and automate welding and assembly workshops. Automatically replenish and return empty boxes.
The information management system is the brain of the entire system, helping them interact and operate most effectively. To refer to software solutions specifically for your factory, please refer0 to:
Improve production management efficiency, reduce costs, and increase flexibility
SAVING 30% COST
Changing from a traditional production line to autonomous mobile robots AMR has saved 30% of the production line cost through the intelligent robot management system, independent material calling is implemented, waiting and excess materials are reduced, saving space and effort.
GOODS TO PERSON, CONVENIENT AND EFFECTIVE
AMR provides necessary materials directly to workers operating under the “goods to person” method instead of “person to goods”, reducing the time people have to search for and transport goods. AMR brings materials to the location to help reduce work intensity, labor of workers, and improve production efficiency.
CONTROL INTRALOGISTICS SYSTEM IN THE FACTORY: SAFE AND ORDERLY
Various scenarios of operation of many types of AMR robots are deployed at the same time and place, the control of this ‘traffic’ will be carried out by the RCS robot management brain, ensuring orderly paths between humans and robots, avoiding congestion and collisions, optimizing distribution efficiency.
A successful AMR project requires an understanding of customer needs, factory operations, dedication, and effort from both customers and Rozitek. We, with all our effort and effort, along with strategic partners, commit to bringing the most suitable solutions to customers. Contact us today!