1 Forklifts Removed from Operation
2 HC reallocated to high value tasks
99.4% average uptime over 2 years of operation
12.5% Improvement in overall productivity<5/span>

Global automaker improves productivity by 12.5% with MAG Lifter Solution

1 Forklifts Removed from Operation
2 HC reallocated to high value tasks
99.4% average uptime over 2 years of operation
12.5% Improvement in overall productivity

The Problem

A global automaker had been facing labor shortage issues which was affecting their ability to maintain productivity. To alleviate such labor constraints, they had started exploring AMR solutions to take over certain intralogistics processes in their body shop process.

However, since the processes in question are mission-critical, they were concerned about whether an AMR system could meet their performance requirements.

Our Solution

How SyncOS ensured a successful deployment

SyncOS was able to track the status of the different systems involved in the automation process (AMRs, call panels, assembly line) and then intelligently assign tasks to the MAG AMRs to ensure optimum productivity. This was critical in achieving the 12.5% productivity improvement

Key Features
Cycle time mapping:

Cycle time mapping:

We mapped assembly line operations to the AMR process in detail to ensure timely delivery of parts to the lineside and avoid any production downtime.

Operator <> AMR interaction:

Operator <> AMR interaction:

We reduced usage complexity for the assembly & forklift operators by translating the interface to Thai and reducing the number of steps to just 1 or 2 clicks

Ensuring high uptime:

Ensuring high uptime:

We defined the process and integrations clearly to ensure a 99%+ uptime

Impact On Operations

  • Increased production capacity by 12.5%, from 28 to 32 JPH, ensuring higher throughput.
  • Maintained 99.4% uptime, supporting uninterrupted operations for over 24 months.
  • Delivered over 1 million parts to the lineside with 193,000 production trips, ensuring timely assembly line support.
  • Simplified operator interactions with localized interfaces, reducing steps to just 1–2 clicksfor ease of use.
  • Reallocated 1 forklift and 2 operators, optimizing labor resources.
  • Achieved ROI in under 2 years, making the AMR solution highly cost-effective.

Conclusion

The deployment of Botsync’s AMR solution has transformed the customer’s body shop operations, enabling them to overcome labor shortages while achieving significant productivity gains. With over 193,000 production trips and 1 million parts delivered to the lineside, the solution has proven its reliability and efficiency, maintaining uptime above 99%.

This success demonstrates how AMR-driven automation can seamlessly integrate into mission- critical processes, improve operational capacity, and deliver rapid ROI, all while optimizing resource utilization for sustainable growth.

Case Studies