Interesting New AGV Applications: Where to Start

Transcription

1 Interesting New AGV Applications: Where to Start Presented by: Sponsored by: Mark Longacre, Marketing Manager - JBT Corporation Brian Keiger- Grenzebach Corporation 2014 MHI Copyright claimed as to audiovisual works of seminar sessions and sound recordings of seminar sessions. All rights reserved.

2 New AGV Applications Automatic Carts at Retail DC (Macy s) Moving Heavy Aluminum Ingots Tote/Carton Handling for Injection Molding Operation in a Hospital Delivery of Aircraft Subassemblies Transport of Building Materials in Manufacturing Beverage Distribution Center Automation Trailer Unloading of Raw Mt ls and Loading of Finished Goods Raw Material Delivery for Paper Mill Converting Food/Ingredient Manufacturing Automotive Parts Manufacturing Grocery Distribution Product Movement Automated Warehousing

3 Automatic Guided Carts Help 750,000 sq. ft. warehouse 6 AGCs tug furniture on trains of carts to/from dock doors AGCs also move empty carts back to loading bays Features auto coupling & decoupling hitch Flexible magnetic tape guidance 24/7 with Automatic Opportunity Charging Charges during 4-minute stops at 3 drop zones Macy s DC

4 Automatic Guided Carts Help Macy s DC Project Benefits Previously used man aboard tuggers On-time order fulfillment increased to 99% Overall productivity increased 22% Reduced overtime ROI achieved within 12 months of commissioning Helped achieve LEAN objectives

5 AGVs Move Heavy Loads in Aluminum Plant Two heavy-duty AGVs move 95,000 lb. ingots that are 900 degrees F AGVs have 4-wheel independent electronic steering allowing them to move in any direction System features dual laser navigation scanners for a 360 degree field of view

6 AGVs Move Heavy Loads in Aluminum Plant Project Benefits Minimizes number of times ingots are handled, reducing damage. Improved safety compared to overhead cranes and fork trucks Significantly reduces employee accidents Increases productivity Flexibility able to easily change guidepath Durability in harsh environment

7 Tote/Carton Handling AGV System Plastic parts manufacturing: The AGVs transport empty totes and boxes to the injection molding machines and finished goods from the machines to the pack-out area. Jobs are generated as the operator enters a print request for a label after checking product quality. AGVs are capable of carrying three totes or boxes. Transfer is possible on both sides of the vehicle, using extractable shuttles and passive P&D stations. System data: 20 Unit Load AGVs Inertial navigation Opportunity battery charging Belt conveyor vehicle transfer mechanism

8 Hospital AGV System Hospital with 1,415 beds 7 main buildings 1 Distribution center 8 Logistic depots Performance data: Can handle 3,900 transports daily 1,200 Miles traveled daily Longest route ~1/2 mile Max. load 1,000 lbs. Scope of supply: 81 AGV (1,6 m/s / 275 fpm) Flexible inertial navigation 60 Opportunity charging stations 216 Send/Receive stations 1,150+ carts

9 Parts Handling AGV System Airplane parts manufacturing: The AGVs transport airplane parts (e.g., wing slats) throughout the manufacturing and assembly areas. AGVs are capable of carrying large, bulky items. Transfer is possible at multiple levels, such as the floor or a stand. System data: 2500 kg (5,500 lbs) Laser Guidance Forward / Backward Movement 180 turn in a very small space (9 m to a team of about 7 m) Position Accuracy of ±0.5mm

10 Parts Handling AGV System Building material manufacturing: The AGVs transport building materials (e.g., racking, supports, etc.) throughout the manufacturing and assembly areas. AGVs are capable of carrying large, bulky items. Transfer is possible from both sides of the vehicle and across multiple conveyors. System data: 3000 kg (6,600 lbs) Multi-Conveyor Inertial Guidance Omni-Directional Movement 180 turn in a very small space (9 m to a team of about 7 m) Position Accuracy of ±0.5mm Product Traceability

11 Beverage Distribution Center 780,000 sq. ft. warehouse Average Inventory = 700,000 cases 5 laser guided AGVs store/retrieve product in lanes Product block stacked up to 4 high AGV mounted bar code scanner identifies pallet Integrated with WMS Benefits Improved inventory accuracy Fewer repairs Reduction in breakage & energy costs Flexibility/scalability/mobility Payback 1.5 yrs

12 Beverage Process/Bottling Trailer Loading 20 AGVs with single double attachment Finished goods handling Pick up pallets from 12 stretch wrappers Deliver pallets onto trailers at 15 bays Also delivers pallets to temporary buffer storage (35 lanes) Standard over-the-road trailers Accommodates multiple loading patterns Trailer Unloading 4 AGVs with single double attachment Pallets of empty bottles Automatic delivery to bottling lines

13 Paper Mill/Paper Converting Challenge: For quality purposes, each finished run from over 10 sheeters requires a pallet the same dimensions as the paper sheets. The customer builds all their own pallets creating significant variance in size, shape, and height. The result can be over 100 different pallet configurations. System Solution: Database of key pallet profiles and locations The host computer relays pallet profile to AGV for pick up Sensing solution on the AGV identifies/reconfirms size, shape and location of fork pockets Fork AGVs with ability to shift forks side to side and also change widths between the forks Opportunity charging and fully automated battery swap system Results: Increased throughput, reduction in labor Full tracking of WIP/FG from raw roll to dock door 2 Year ROI

14 Food/Ingredient Manufacturing Challenge: The customer manages thousands of spice and condiment SKUs and must keep them moving from receiving to storage and through production with each location having different heights. System solution: Two new FlexFork AGVs with wireless navigation Non-contact laser sensors for obstacle detection and avoidance AGV self-monitoring battery voltage levels Interfaced with customer existing ERP system Results: Significant reduction in waste from forklift/driver damage Real time tracking of materials throughout facility even during moves Scalable system to grow/change as production needs change

15 Automotive Parts Manufacturing Challenge and Needs: Deploy a process that would increase efficiency and reduce the overall cost of material handling. Adaptable and flexible solution for ever-changing floor and facility layouts. Solution: 10 Flexible AGVs Two tow tractors transport product between manufacturing processes. Three tow tractors transport inbound freight from the support facility and deliver within the manufacturing area. Four double length pallet trucks move product from manufacturing to shipping areas to the shipping staging lanes. One single length pallet truck with towing attachment transports empty racks on carts to the manufacturing line and brings finished product back to the finished goods store.

16 Automotive Parts Manufacturing Results: Increased Efficiency: Flexible AGV fleet provides a consistent flow of internal component movements as well as inventory reduction due to more frequent deliveries to the manufacturing lines. Reduced Cost: With flexible AGVs improving overall efficiency, there is an overall reduction in material handling cost. Improved Safety: Flexible AGVs deliver automotive parts reliably and in a predictable manner. The use of AGVs eliminates employee, product, and facility damage, creating a safer work environment. 4 AGVs 5 AGVs 1 AGV

17 Grocery Distribution Challenge and Needs: Eliminate wasted hi-lift travel from the reserve back to the dock. Improve efficiency in the distribution center, reduction in hi-lift travel time Solution: 8 Flexible AGVs 20-30% of all inbound freight is handled by flexible AGV double length pallet trucks. AGV pallet trucks are utilized for inbound delivery of pallets in the DC Results: Increased productivity with replenishment hi-lifts in aisles because operators now have more products to move in shorter distances. Reduced manned travel from putaway by 20-30% and increased hi-lift pallet per hour by 20%. Team members reallocated to more valueadded roles in the DC such as replenishment and selection.

18 Automated Warehousing Complete Storage Automation Production buffer warehouse Integrated conveyor sortation system Deep lane storage with staging to outbound docks 25 Clamp AGVs AGV management software integrated with WMS

19 Automated Warehousing Project Benefits Reduced labor and supervisory costs Improved material tracking Reduced damage to facility, equipment, & product Two year payback

20 Where to Start? Define Goals and Objectives Develop Preliminary Layout Define Loads and Transfer Points Create Distance and Frequency Matrix How Should Movement Requests be Generated? What Future Changes are Expected?

21 Where to Start Define Project Goals and Objectives What issues are driving the project? e.g. capacity increase, labor costs reduction, throughput increase, track product, reduce damage, etc. What specific goals/objectives must be attained to proceed? e.g. ROI, payback, safety improvements, etc. Develop preliminary project schedule. Consider phased implementation and avoid peaks in activity Compare AGV solution vs other automated and non automated solutions

22 Where to Start Develop Facility Layout Drawing showing Transfer points (Pick up and delivery locations) Preliminary vehicle paths Drawing scale or travel distances Doors, low height clearances, equipment interferences Aisle widths Key intersections with other vehicle and pedestrian traffic

23 Where to Start Detailed Load Information for Each Load Type pallet, container, skid, bin, roll, slip sheet Weight max, min, average Dimensions length x width x height Stability leaning, product overhang past base (pallet) Fork opening dimensions Transfer Point Definition Type floor, stand, conveyor, racking, etc. Height

24 Where to Start Transport Distance Matrix Corresponding to positions shown on the facility layout drawing, calculate distance between all pick-up and delivery points All distances in meters Delivery Point 1 Delivery Point 2 Delivery Point 3 Delivery Point 4 Delivery Point 5 Pick-up Point Pick-up Point Pick-up Point Pick-up Point Pick-up Point

25 Where to Start Transport Frequency Matrix Corresponding to positions shown on the facility layout drawing, determine the number of deliveries per period of time that is required to support operations Develop data for both average and peak conditions Deliveries per hour Delivery Point 1 Delivery Point 2 Delivery Point 3 Delivery Point 4 Delivery Point 5 Pick-up Point Pick-up Point Pick-up Point Pick-up Point Pick-up Point

26 Where to Start How are Material Movement Orders Created? Enterprise Resource Planning (ERP) System SAP Warehouse Management System (WMS) Red Prairie Input/Output (I/O) Sensor - barcode Operator Driven Call buttons, handheld, other Other considerations Will AGV System Management software track inventory? Special software integration requirements

27 Where to Start Considerations for Future AGVS are generally very scalable and flexible for future changes Are capacity increases or decreases planned for the near future? Are there ERP/MRP/WMS business software changes expected? Are facility layout changes expected?

28 Where to Start Contact an MHI AGVS Member Company

29 For More Information: Contact AGVS MHI Managing Executive Gary Forger Automatic Guided Vehicle Systems (AGVS) Product Section