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© 2014 MHI®
Copyright claimed as to audiovisual works of seminar sessions and
sound recordings of seminar sessions. All rights reserved.
Sponsored by: Presented by:
Bruce Buscher
Vice President of Sales
Smart Handling System Group
How Can Automatic
Guided Carts Help
Your Business
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Benefits of AGCs in Manufacturing, Warehouse &
Distribution Environments
• Ergonomics of the job
• Cost reductions
– Reduction of non-value added operations
• Reduction of lift trucks
• Flexibility in processes
• Expansion Capabilities
• Cost of Ownership to Automate is Reduced
• Implementation of Systems is Reduced
• Software Integration is Easier
• Safety of Plant Employees
Alternatives to using AGCs
• Tow lines
• Powered conveyor
• Lift trucks
• Manual tugger
Researching AGC Solutions
• Customer site visits
• Manufacturers’
websites
• Sales brochures
• White papers
• Technical articles
• You Tube
• Inside Tesla video
Benefits of AGCs for Material Handling
• Flexible Load Handling
Options
• Easy installation
• Cleaner and quieter than
conventional conveyors
• No barriers
• Easily scalable
• Easy modifications
AGC Applications
Delivery Systems
Order Picking
Conveying Product
Palletizing a Load
Moving Totes
Stretch Wrapping Loads
Moving Pallet Jacks
Supermarket & Kitting in Manufacturing
• Kitting Parts for assembly type operations
• Automated Kitting in a Lean Environment
AGCs with Integrated Conveying
• Conveyors on AGCs / AGVs is common
– Eliminates Fork Truck Traffic
– Creates Safe Environment for Operators
– Moves Totes or Pallets
– Nothing is permanently attached to Floor
• Provides flexibility within a Plant or Warehouse Layout
AGCs Used in Order Picking
• Required Manual Order Picking Systems
– Receiving and Acknowledging the Order to be
Picked
– What do you load the Product or Order onto?
– Minimizing the Moves of the Order Picker
– Using Lift Decks to Help Ergonomics of
Picking
– Keeping the Order Picker Moving in the
Process
AGCs Moving Pallet Jacks
• Pallet Jacks Used Heavily in Warehouses
– Injuries due to Heavy Loads using Pallet Jacks
– Operators moving a Pallet Jack Loads adds NO Value
– Using and AGC to Move the Pallet Jack Loads
AGCs in Train Delivery Systems
• Trains are used in Warehouse & Distribution
• AGCs Replace the Man Aboard Tugger or Lift Truck
• Loading Trains
– Done Manually
– Automatically
– Auto Couple/Decouple
trains
Case Study: Delivery System
• Application: – Automotive seat and door panel assembly
• Old Method
– Gravity conveyor with part racks, bins and shelving
• Assembly Issues
– No flexibility in assembly line
– Multiple assembly lines
– Excess inventory on assembly line
– Need to shorten production time
Case Study: Delivery System
• Challenges:
– Reduce inventory
– Reduce body movement of operator
– Increase in production volume
– Flexible assembly process
– ROI: 12 months or less
– Eliminate non-value add moves
Case Study: Delivery System
• Possible Solutions
– Powered roller conveyor
– Tunnel AGC delivery system
– Push Carts or Racks
• Ultimate Solution
– Tunnel AGC delivery system
Case Study: Delivery System
Case Study: Delivery System
• AGC Line Layout & Results
– Phase I and Phase II
• Plant 1 to Plant 2 Material Delivery,(19) AGCs
Case Study: Delivery System Phase II
• Project results – Went from 19 to 25 AGCs in the system
– Traffic control
– PLC Interface with wireless pushbuttons
– Approximately (20) intersections
– Approximately $750,000 for equipment, engineering, installation
• Reduction of: – (7) Workers/shift x 2 shifts
– (4) Four fork trucks
• Less than one year ROI
Case Study: Delivery System
• Phase III
– Picking station to line side
delivery
– AGCs move seat pallets
station to station
• 17 more AGCs Intersecting
Paths with TBIN to TISA
Material Handling AGC
Application
Case Study: Warehouse and Shipping
• Old System
– Man Aboard Tugger
– System Issues
• Space in Warehouse
• Lots of extra Trailers
• No Consistency in
Product Movement
• Possible Solutions
– Floor Conveyor
– Tow Line
– Man Aboard Tugging
– AGC/AGV System
Case Study: Warehouse Pallet Movement
• Old System
– Single and Dual Fork Trucks
– System Issues
• Safety of People, Fork truck Traffic, Accidents due to Congestion
• Possible Solutions
– No Change
– Floor Conveyor
– Overhead Conveyor with Elevators
– Delivery Trains
• Solution of Choice
– Dual AGC with Conveyor
For More Information:
Speaker email: [email protected]
Website: www.daifukuwebb.com
Or visit MODEX 2014 Booth #4918
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speaker’s email address/home page, the Exhibiting Member Company’s name,
home page and Booth Number.
