A FlexQube Inc. customer runs a mixed-model assembly line producing many different variants of truck cabs in terms of size, color, and options. The high level of variation resulted in a complex material-handling process because the large number of parts that must be delivered to the assembly line.
The vehicle maker must present parts for lineside replenishment within picking reach next to the assembler. Since storage space is limited around the assembly line, it must prepare most materials at the supplier or an internal picking area.
The manufacturer then delivers them as a kit of parts, explained FlexQube. Every 10 minutes, manually driven forklifts used to pick up, transport, and drop off the racks at the assembly line.
It used a two-bin system, meaning there are two rack locations at each point of use. When one is empty, the assembler can pick from the second one while the first one is replenished.
FlexQube Navigator automates transport in two steps
Using the FlexQube Navigator autonomous mobile robot (AMR), the customer can automate the transport of material racks with different sizes, shapes, and weights.
Navigator can connect to modular and motorized Load Carriers that are customized for the seats and door racks. The AMR can then navigate with them, said Duncan, N.C.-based FlexQube.
The company said it took a building-block approach to designing two different Load Carriers: one for the seats, a different one for the door racks. Despite the difference in size between them, the same Navigator AMR can move both racks.
Once the Navigator is coupled with the Load Carrier, it lifts itself from the floor and transfers power and navigation data to the Load Carriers.
Vehicle maker sees results
FlexQube said its AMR can navigate throughout the factory without floor markings. In addition, the system can automatically pick up, drop off, and move up to seven different-sized Load Carriers between 1.2 x 1.2 m (16 sq. ft.) and 2.5 x 2.5 m (67.2 sq. ft.) with the same Navigator.
The customer said it appreciates the small footprint of the Navigator AMR when traversing the facility without a Load Carrier in tow.
It calculated the return on investment (ROI) for FlexQube’s system to be 1.2 years for three shifts, 1.8 years for two shifts, and 3.3 years for one shift, when replacing a fork truck and driver.