Warehouse
44 pallets per hour operation
5 Fleet of AMRs
24/7 Operations @ 99% uptime
3 forklifts and 9 forklift operators reallocated to new operations

Revolutionizing Pallet Transfer for a Global Beverage Leader using integrated AMR and software solutions

Our client is a globally recognized soft drink brand with a diverse product portfolio, renowned for innovative marketing and memorable advertising campaigns. Their products are sold in over 200 countries, making them world leaders in the beverage industry.

44 pallets per hour operation
5 Fleet of AMRs
24/7 Operations @ 99% uptime
3 forklifts and 9 forklift operators reallocated to new operations

The Problem

Our client’s factory faced significant challenges when it came to the transfer of heavy pallets, which led to a dependence on forklifts. Operating in a narrow, constrained environment increased the risk of safety incidents due to the high number of forklifts. Additionally, ensuring business continuity was difficult, as maintaining production volumes required trained workers to operate across three shifts. The client wanted a solution to maintain quality and productivity while reducing manpower dependency.

Our Solution

Integrated MAG1000 Conveyor Solution

Botsync designed an AMR solution in collaboration with our partner to transfer finished goods (FG) pallets safely and reliably from the production line to the warehouse. These pallets came from two separate areas within the factory, with some needing to be strapped before storage. By integrating SyncOS™ with conveyor strapping cells and MAG1000 AMRs, Botsync ensured seamless operations.

Key Features
Highly integrated & fully automated

Highly integrated & fully automated

We used the SyncOS™ Integrator to integrate with the site’s Conveyor and Strapping PLCs via Kepware, the SyncOS™ Fleet Manager, the SCADA system, and the overall WMS. This allowed us to create a well integrated and robust automation solution

Highly configurable

Highly configurable

The MAG fleet needed to carefully handle the unstrapped pallets to ensure safety of the finished goods, while still transporting them at the maximum speed to ensure throughput is maintained. With SyncOS™ we were able to configure the system to dynamically configure the MAG speed depending on the type of the load being transported.

Intelligent orchestration

Intelligent orchestration

Operating in a congested environment with multiple AMRs, the solution required advanced fleet management with intelligent task prioritization. Thanks to SyncOS™, we were able to prioritize tasks based on each machine’s capacity and restrictions, to ensure optimal utilization of their capacity.

Impact On Operations

  • Reduced need for forklifts, significantly minimizing the risk of safety incidents.
  • Reallocation of 3 forklift drivers and 9 forklift operators, which led to maintenance of production throughput with fewer human resources.
  • Improved production quality due to reduced human interaction with the finished goods

Conclusion
Botsync’s integrated AMR and software solution revolutionized our client’s operations, improving safety and efficiency while allowing them to maintain high throughput with fewer personnel. The successful deployment highlights how automation can optimize workflows in constrained environments, paving the way for scalable growth.

Case Studies