1 Forklifts Removed from Operation
2 HC reallocated to high value tasks
<2 Years to attain ROI
<15 Min for any support turnaround

Global automaker achieves ROI in under 2 years with MAG trailer transfer solution

1 Forklifts Removed from Operation
2 HC reallocated to high value tasks
<2 Years to attain ROI
<15 Min for any support turnaround

The Problem

One of the world's largest automakers faced a significant challenge at their Thailand facility: automating the transportation of trailers, each weighing over 2 tonnes when fully loaded with car parts, to the marketplace every 3.5 minutes.

This mission-critical operation required a reliable and efficient AMR solution, especially as it would be the automaker's first deployment of an AMR system outside of Europe and North America. After careful evaluation, they approached Botsync, and we identified an AMR solution capable of meeting this demanding task.

Our Solution

SyncOS ensured a successful deployment

As with most complex automation projects, the capability of the software platform plays a huge role in ensuring a successful deployment. With SyncOS , we were able to:

  • Ensure safe and optimized traffic management of the AMR fleet.
  • Integrate the AMRs to customized interfaces, call panels, traffic lights and safety scanners to create an intelligent and safe solution.
  • Provide detailed insights on performance which were used to further improve AMR cycle times.
Key Features
Takt time of operations and required AMR bot count:

Takt time of operations and required AMR bot count:

We conducted onsite time studies and detailed simulations to ensure that the AMR system could meet the production requirements.

Operator <> AMR interaction:

Operator <> AMR interaction:

We translated the interface to Thai and designed the UI to allow task assignment in just a few clicks

Safety of overall system:

Safety of overall system:

Safety of the AMR itself often doesn’t guarantee overall safety of the process. To ensure a safe 24/7 operation, we designed an interlock system to restrict AMR movement during loading and unloading of the trailers.

Impact On Operations

  • Completed over 40,000 production tripsin 15 months, ensuring seamless delivery of parts.
  • Delivered over 1.2 million stamping parts from the stamping line to the marketplace.
  • Enabled reallocation of 1 forklift and 2 forklift operators, optimizing labor resources.
  • Achieved ROI in under 2 years, demonstrating cost-effectiveness and operational efficiency.

Conclusion
Botsync’s AMR deployment successfully addressed the automaker’s challenge of automating mission-critical trailer transport. By combining advanced hardware with SyncOS , we delivered a safe, efficient, and scalable solution that optimized workflows, reduced manual dependency, and ensured long-term reliability. This project underscores the value of tailored automation in transforming complex industrial processes.

Case Studies