Case Study: Industrial Automation with AMRs and 6DOF Robots
Client: Leading Automotive Component Manufacturer
Objective: Improve production line efficiency and reduce manual labor in part handling and assembly
Challenges Faced
The client’s production facility was struggling with:
- Excessive manual intervention for moving heavy components between machining and assembly stations.
- High cycle time, leading to production bottlenecks during peak demand.
- Workplace safety risks, with operators manually handling heavy and delicate parts.
- Difficulty scaling operations across multiple production lines without significant manpower increases.
Solution Implemented
Kyron Automation designed and deployed a fully integrated Industry 4.0 solution combining:
- Autonomous Mobile Robots (AMRs): Optimized for transporting machined components between multiple workstations with real-time route adjustments.
- 6DOF Robotic Arms: For precision part picking, orientation correction, and seamless assembly tasks at designated cells.
- Central Control System: A proprietary orchestration layer enabling real-time task allocation, live status monitoring, and coordination between AMRs and robotic arms.
Key Highlights
- Reduced human intervention by 60% in material transport
- Improved cycle time by 25% through synchronized AMR and robot operations
- Enabled 24×7 operation with minimal downtime
- Scalable architecture for future expansion across multiple production lines
Outcome
The project resulted in immediate improvements in:
- Throughput: Faster part movement and assembly cycles. Reduced human intervention by 60% in material transport
- Quality consistency: Robotic arms ensured repeatable, error-free assembly.
- Operator safety: Significant reduction in manual handling of heavy components.
- Improved cycle time by 25% through synchronized AMR and robot operations
- Enabled 24×7 operation with minimal downtime
- Scalable architecture for future expansion across multiple production lines
The ROI was achieved in under 8 months, and the client has since scaled the solution to additional production lines—setting a benchmark for smart manufacturing within their group.