Warehouse
211 Km traveled per day
1 operator re-allocated to other operations
2 Years Return on Investment

Global automotive safety suppliers uses MAG300 Lifter to automated transfer of laser cut materials

The customer is one of the world’s largest automotive safety suppliers, with operations in 25 countries. They specialize in the design, development, and manufacture of leading passive safety systems for the automotive industry. With over 70,000 employees worldwide, they are a key player in ensuring automotive safety standards.

211 Km traveled per day
1 operator re-allocated to other operations
2 Years Return on Investment

The Problem

The company relied on operators to manually move heavy trolleys loaded with laser-cut parts across the factory. This manual handling posed several challenges:

  • Untimely pick-up and delivery of trolleys, leading to reduced productivity at the machines.
  • Ergonomic risks for operators due to the constant handling of heavy loads.
  • Lack of traceability in tracking when and where items were moved within the factory, leading to inefficiencies in production planning.

Our Solution

Fleet of 3 MAG300 Lifters to Automate Engine Transfer

Botsync designed a solution using a fleet of MAG300 Lifters to automate the transfer of loaded trolleys from the production area to the packaging zone. The trolleys were ergonomically designed for easy loading and unloading by operators, reducing strain and injury risks.

The MAG300 lifter fleet would automatically dock with the trolleys, transporting them to designated drop-off zones. This solution eliminated manual handling and reduced the total walking distance for operators by up to 9 km daily.

Since the AMR delivered items in a timely manner, it reduced waiting time at both the machine cells as well as the packaging area, thereby improving overall productivity

Key Features
Navigation in narrow environments:

Navigation in narrow environments:

The MAG300 is designed to operate in tight and congested factory environments, allowing automation without the need for changes to the facility's layout. This ensured that the production space remained uncompromised while still automating critical processes.

Efficient Deployment with Minimal disruption to operations:

Efficient Deployment with Minimal disruption to operations:

The MAG300 solution was fully deployed within 8 weeks of order confirmation, without requiring any infrastructure modifications. The SyncOS™ Fleet Manager was integrated with the client’s server using advanced cybersecurity protocols, allowing for a smooth and secure installation. The intelligent navigation and mapping system enabled Botsync’s operations team to bring the solution into production within a week. Thanks to comprehensive training and an intuitive user interface, the customer’s operators were able to quickly learn and adopt the system, making the transition seamless.

Impact On Operations

  • Reduction of 1 operator: The solution allowed the reallocation of 1 operator to other operations, improving resource efficiency.
  • 24-month ROI: The automated solution achieved a return on investment within 24 months, demonstrating the financial benefits of automation.
  • Reduction of walking distance by 9 km daily: Automation reduced the physical strain on workers, improving productivity and operational flow.

Conclusion
The deployment of Botsync's MAG300 fleet transformed the client's material transfer process by automating the transportation of laser-cut parts. By reducing manual labor, improving operator safety, and streamlining production flow, the solution delivered measurable productivity gains and cost savings with a clear ROI in just two years. This case highlights the importance of automation in large-scale manufacturing environments where efficiency and ergonomics are critical to success.

Case Studies