FlexQube AMRs help automotive manufacturer reduce forklift traffic

At one automaker’s facility, many workers spend hours constantly bringing seats and doors to a cab assembly line. This task, which includes diverse materials of varying sizes, results in high forklift traffic, added complexity and safety risks to the assembly process.

The manufacturer hoped to automate the task for five reasons in particular:

• High product variation: Many different cab sizes, colors, and options increase complexity in sequencing and material delivery.
• Complex material handling: Large number of parts must arrive in the right order and within easy reach of assemblers.
• Limited line-side storage: Forcing reliance on pre-kitting from suppliers or internal picking areas.
• Frequent replenishment needs: Seats and doors require constant refilling around every 10 minutes.
• Manual forklift dependency: drivers must track rack levels, transport them, and replace them, making the process labor-intensive and prone to inefficiency.

The team selected Gothenburg, Sweden-based FlexQube to automate the process.

Forklifts present unique safety challenges

One of the main reasons the vehicle manufacturer looked to FlexQube was the need to find forklift alternatives. Manufacturing is the most common industry for forklift fatalities, representing 42% of all deaths.

According to statistics, there are 35,000 to 62,000 injuries and around 90 fatal accidents yearly involving forklifts.

Despite this, forklifts remain the most common way to move large, heavy racks from warehouses to assembly lines, since tugger trains pose ergonomic challenges where operators must manually move loaded carts from the train to the point of use. So, the project scope included replacing the forklifts used in the assembly line with an automated system.

FlexQube AMRs can handle a variety of payloads

With its patented Navigator system, FlexQube said it can automate transport solution to move material racks with different size, shape and weight. One small and standardized robot can, through a standardized coupling, navigate modular and motorized Load Carriers.

The FlexQube AMR System is based on a modular “one robot/multi-carrier” concept. This means the autonomous mobile robot (AMR) itself is a non-load carrying system, equipped with a safety system, a navigation system, and a battery.

The robot can couple with FlexQube’s wide range of motorized Load Carriers through a standardized interface, transferring power and data to the Load Carrier motors and enabling it to navigate.

To automate the process, FlexQube designed two Load Carrier robots for seats (1,610×1,610 mm) and doors (1,880×2,450 mm) using its building-block system. The standalone Navigator AMR can transport both rack types via the coupling interface, despite their size differences.

Here’s a step-by-step breakdown of how the process works:

• An assembler pushes a button to start a mission.
• An AMR picks up a Load Carrier with empty rack.
• The robot moves the Load Carrier to the warehouse.
• The AMR drops off the Load Carrier with an empty rack.
• Next, the robot picks up a Load Carrier with a full rack.
• Then the AMR transports full rack to assembly line.
• Finally, it goes to a home/charging station.

FlexQube achieves 99% uptime

FlexQube claimed that its AMR system has replaced forklifts, transporting modular seat and door racks of varying sizes and weights directly to the assembly line. This improved safety, reduced forklift traffic in high-density areas, ensured 99% uptime and enhanced picking ergonomics for assemblers, the company said.

FlexQube said key benefits of the deployment included:

• Clear ROI: The company predicted a return on investment between one to three years, depending on the number of shifts.
• Operational savings: FlexQube estimated $68,000 savings per year for each forklift replaced.
• Safety: A unique, patented PLd-rated (Performance Level d) feature identifies Load Carrier size on the fly and automatically adapts the AMR’s safety fields.
• Small footprint and high flexibility: One small AMR with standard coupling can move any size of Load Carrier, said FlexQube.