How to Utilize AGVs and AMRs in the Factory? Explaining the Implementation Challenges and Key Considerations for Achieving Inter-process Transportation.

AGVs and AMRs, which are frequently used in logistics settings, are also garnering attention for their adoption in manufacturing factories. By automating inter-process transportation, various benefits such as improved productivity and reduced workload for workers can be expected. In this article, we will introduce the requirements, benefits, and key considerations when implementing AGVs and AMRs in factory settings.

AGVs and AMRs: Gaining Attention in Manufacturing Factories

The logistics industry has been focusing on the adoption of AGVs (Automatic Guided Vehicles) and AMRs (Autonomous Mobile Robots) to achieve labor reduction in internal logistics operations. Similarly, in manufacturing factories, where various components, materials, and work-in-progress items move between different processes, the automation of inter-process transportation using AGVs and AMRs is gaining traction. Labor shortage is a significant challenge in the manufacturing industry as well, making the implementation of AGVs highly desirable for labor reduction and productivity improvement.

For a foundational understanding of AGVs and AMRs for achieving labor reduction in internal logistics, refer to the following explanation

Differences in Utilizing AGVs and AMRs between Logistics and Manufacturing Settings

How do the utilization methods of AGVs and AMRs differ between logistics and manufacturing settings?

Firstly, it is important to note that factories also have logistics processes, which include common tasks such as material and component storage and finished goods shipment.
The major difference lies in the presence or absence of transportation processes between manufacturing processes such as production and assembly. In factories, transportation processes occur when work-in-progress items received from the previous process are processed and passed on to the next process. On the other hand, logistics facilities do not involve such transportation processes as they are not involved in manufacturing. Consequently, in manufacturing factories, various items such as materials, work-in-progress items, and finished goods are transported across processes in a complex manner. Time-consuming transportation can lead to temporary production stoppages due to unavailability of materials and components, thereby reducing the overall productivity of the production line.

Considering these factors, the introduction of AGVs for material supply, production, assembly, and other processes is gaining attention as a means to enhance productivity on production lines in factories. The following sections will explain the benefits of implementing AGVs and AMRs in manufacturing factories and the requirements for their implementation.

Three Benefits of Implementing AGVs and AMRs in Factories

Implementing AGVs and AMRs in factories offers the following three benefits

Reduction in Part Supply Delays

In production lines, work pace is predetermined, and delays in part supply can disrupt the production flow. When parts are supplied by manual transportation, the possibility of human errors, such as misplacement, cannot be completely eliminated, and the work pace can vary depending on the proficiency of the workers. By introducing AGVs and AMRs, parts can be transported consistently at a steady pace, avoiding situations where part supply falls behind the speed of workers or production equipment.

Reduction in Physical Burden in Transportation Processes

Workers no longer need to physically walk around or move heavy carts for transportation, significantly reducing their physical burden. Furthermore, the introduction of AGVs and AMRs improves safety by minimizing the risk of accidents resulting from worker fatigue, which can accumulate during manual transportation.

Efficient Utilization of Human Resources

Automating part supply and finished goods transportation processes with AGVs and AMRs allows for a reduction in the number of workers involved in transportation tasks. Since the primary focus of a factory is production activities, staff previously engaged in transportation tasks can be allocated to more productive tasks or understaffed production lines, resulting in efficient utilization of human resources.

Three Requirements for AGVs and AMRs in Factories

There are three requirements for AGVs and AMRs in factory settings

Capability for Handling Multiple Varieties and Small Batch Transportation

The first requirement is the ability to handle multiple varieties and small batch transportation. To streamline inventory management of components and materials in factories, it is necessary to meet the Just-in-Time (JIT) principle of supplying and delivering the ""required items, at the required time, in the required quantity."" AGVs and AMRs capable of agile transportation in small batches are essential for achieving JIT.

Adaptability to Variable Production

The second requirement is the adaptability to variable production. Variable production involves producing a variety of components on a single production line according to the needs and circumstances, rather than manufacturing specific products. Due to the variability in both product types and production quantities, it is crucial to flexibly respond and timely transport the changing types and quantities of materials.

Avoidance of Line Congestion by Matching Production Speed

The third requirement is the ability to avoid line congestion by matching production speed. In factory production lines, there is a possibility of equipment failures or delays in material supply, making it difficult to consistently achieve the theoretically possible production speed (equipment utilization rate). If the timing of work and transportation becomes misaligned due to changes in production speed, line congestion can occur. Therefore, AGVs and AMRs that can adjust transportation timing flexibly are required.

Key Considerations when Implementing AGVs and AMRs in Factories

When implementing AGVs and AMRs, it is important to first examine case studies and use cases to gain a clear understanding of process automation. Clarify the objectives, benefits (such as labor shortage resolution and increased equipment utilization), and budget, and then conduct a cost-effectiveness calculation.
Additionally, it is necessary to assign or secure personnel with skills and knowledge related to automation.
In cases where new equipment is introduced, significant changes to existing facilities or production lines may be required. However, AGVs can be designed to optimize their travel paths according to the existing layout, minimizing the need for major modifications.
For more information on considerations for logistics automation, including AGV implementation, refer to the following guidebook

LOGITO: Total Support for AGV and AMR Implementation

""LOGITO,"" the logistics automation solution service provided by Daiichi Jitsugyo, conducts analysis and consulting based on the current situation within your factory, and proposes the optimal equipment and quantity through simulations.
For AGV and AMR implementation, a site survey is conducted to check the feasibility of introducing AGVs and AMRs, considering factors such as the nature of transported goods, surface conditions, and immovable equipment along the routes. Based on the survey findings, the implementation design, including AGV and AMR capabilities, quantity, and route settings, is determined. With end-to-end support from implementation to after-sales, you can have peace of mind in terms of operations.