Warehouse
03 MAG 300 AMRs
15 Engines Produced per hour
24 Hour Operations
2.5 Years Return on Investment

Ashok Leyland
Improved ROI by 70%

Ashok Leyland, headquartered in Chennai, is a leading Indian multinational automotive manufacturer. It ranks as the second-largest commercial vehicle manufacturer in India, the third-largest bus manufacturer globally, and the tenth-largest truck manufacturer worldwide. The company operates seven factories in India and has two overseas plants in the UAE and the UK.

03 MAG 300 AMRs
15 Engines Produced per hour
24 Hour Operations
2.5 Years Return on Investment

The Problem

Ashok Leyland’s engine production process required operators to manually push heavy engines, weighing up to 400 kg, on trolleys from the test cell to the dressing area. The test cell is the section of the factory where each engine undergoes rigorous testing to ensure it meets performance and safety standards before proceeding to the next stage. Once testing is completed, the engines are moved to the dressing area, where final fittings and assembly work take place before they are prepared for delivery.

This task involved multiple operators, creating ergonomic challenges and safety risks. Additionally, engines were not promptly picked up once ready from the test cell, which created bottlenecks at the dressing cell and delayed the delivery timelines. The client sought an automation solution that could efficiently and safely transport the engines, working seamlessly alongside human operators to eliminate delays and improve operational efficiency.

Our Solution

Fleet of 3 MAG300 Lifters to Automate Engine Transfer

Botsync designed a solution that utilized 3 MAG300 Lifters alongside a custom designed call panel system. The call panels were designed to let the operators confirm whenever an engine is ready for pickup. The system which was integrated with SyncOS™ would then automatically assign the most suitable MAG300 AMR to pick up the engine and transport it to the dressing area for further processing. 

In parallel, SyncOS™ would also instruct the MAG fleet to deliver an empty trolley to the original pick up point to ensure that the operators are able to continue their operations without any downtime.

Key Features
MAG Fleet Integrated with Call Panels

MAG Fleet Integrated with Call Panels

The SyncOS™ Integrator was used to integrate the MAG300 Lifter fleet with the call panels placed across the facility. This made it intuitive for users to assign tasks to the AMR fleet without worrying about system complexities.

Agile and Easily Configurable

Agile and Easily Configurable

The MAG300 does not require any infrastructural sensors such as tape or QR code for its navigation. This made it very easy for the user to reconfigure or add new workflows as needed.

Intuitive User Interface

Intuitive User Interface

With SyncOS™’s simple UI design, users are able to easily add new tasks and resolve errors independently, without waiting for technicians.

Integrated with Remote Support:

Integrated with Remote Support:

With support from our customer, we were able to integrate the deployed solution with our remote monitoring system. This allows our team to proactively monitor the operation for any errors and resolve them as soon as they come up, thereby ensuring that uptime of operations is always above 99%.

Impact On Operations

  • Reduced waiting time for engines by 1%, which allowed the facility to increase their monthly output by 2-3 engines.
  • Improved overall safety of operations by reducing the risk of accidents such as engine fall which could potentially injure operators.
  • System reduced physically strenuous tasks for operators, contributing to a safer and healthier work environment.

Conclusion
The deployment of Botsync's MAG300 fleet has transformed Ashok Leyland's engine transportation process, optimizing workflows between the test cell and dressing area. By automating the transfer of heavy engines and minimizing downtime, the company improved productivity, safety, and employee well-being. The solution not only increased engine output but also reduced manual labor and safety risks, offering a scalable and efficient automation solution with an impressive ROI within 2.5 years.

Case Studies