agvs: offering the complete solution -...

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Welcome to Session 133

Sponsored by: Presented by:

Patrick (Pat) Conway

Director, Global Business

Development

AGVs: Offering the Complete Solution

Seminar Agenda

• What is an AGV?

• How do AGV Systems work?

• Where have AGVs been used?

• Where are AGVs being used now?

• Examples of applications where AGVs provide the “complete” solution

• What are some features of AGVs?

• What are the benefits of using AGVs?

• Questions

What is an AGV?

• AGV - Automatic Guided Vehicle

• Mobile Robot/Transport Unit

• Unmanned / Fully Computer

Controlled & Real Time Monitored

• Battery Powered

• Intended to replace a person on a manual truck

• Excels at routine, movement of stable loads

• There are typically several vehicles combined with other controls to

make a system

How do AGV Systems Work?

• Vehicles receive instructions from a computer (AGV System Controller)

• 2 way communications with the computer is via RF/Wireless LAN

• Run on virtual guidepaths that can be changed in software

• Guidance systems require little or no floor installation or modifications

• System controller typically provides:

• AGV traffic management

• Interface with customer’s software

• Inventory control and tracking

• Graphical user interface

• Vehicle and system diagnostics

• Client terminal and Web enabled access

How do AGV Systems Work?

System Controls

Ethernet Hub

SYSTEM INTERFACE

AGV-Controller HOTLINE

SERVICE

VPN Support

HUB HUB RF-LAN network

IEEE 802.11B

Warehouse Management System or

Production Control System

• Raw material from receiving to warehouse

• Parts from warehouse to assembly line

• Work-in-process through manufacturing cells

• Finished goods to storage/shipping

• Tooling or dies from storage to manufacturing

Manufacturing Applications

Interface Points • Floor, conveyors, stands, racking

Items Handled • Often custom fixtures or containers

Where have AGVs been used? Manufacturing - Get the right materials to the right place at the right time!

Where have AGVs been used? Typically in Manufacturing Applications

• AGV serve as a “taxi” system responding to I/O requests

• AGVs provide only material movement between processes for product

• Focus is on the vehicle which is customized to handle the unique load size

and interface requirements of applications

• Simple system software relies on communication with the production

control system (PCS)

• PCS handles decision rules regarding what materials are delivered where

• End of Line – linking palletizer, stretch wrapper and finished

goods storage or shipment

• Warehousing – storage and retrieval

• Order Fulfillment in Distribution Centers

• Shipping/Receiving

• Cross Docking

Warehousing and Distribution Applications

Interface Points • Floor, conveyors, stands, racking, block stacking

Items Handled • Typically standard pallets

(i.e.: GMA, Euro,..)

Where are AGVs being used?

Where are AGVs being used? AGV Systems in Warehousing and Distribution Applications

Typically….

• interface with WMS/ERP serving as the most important system contributing to

overall efficiency

• interface with all W&D Systems - often “building bridges” between all automated

systems – thus “driving” operations

• provide not only material movement but also essential full tracking/traceability of

the inventory & transported products

• use standard vehicle designs with load handling actuators very similar to those

on standard fork lift truck models

• incorporate “rules” which allow vehicles to appropriately respond to certain

conditions and keep the system in operation

Examples of applications where AGVs

provide the “complete” solution?

1. End of Line - Moving finished goods from the stretch wrappers to

a) a conveyor leading to a DC

b) buffer storage

c) directly onto a trailer

2. Order Fulfillment – Providing material movements to support mixed

case picking in a Distribution Center

End of Line AGVs delivering the

complete solution

System Summary

• 11 Counterbalanced Vehicles

• Single/Double Load Attachment

• Interface with WMS

• Payback in 2 years

Pickup at Stretch Wrappers

• 10 Locations/2 Pallets

• 40”W x 48”L x 67” H

• 2,500 lb pallets

End of Line AGVs delivering the

complete solution

Stretch Wrapper Pickup

End of Line AGVs delivering the

complete solution

Bridge Conveyor Drop-off

• 8 Locations/2 Pallets

To

DC

End of Line AGVs delivering the

complete solution

Conveyor Dropoff

End of Line AGVs delivering the

complete solution

Temporary Buffer Storage/Retrieval

• Used when conveyor goes down

• 312 Locations – 2 high/3 deep

End of Line AGVs delivering the

complete solution

Conveyor Dropoff

End of Line AGVs delivering the

complete solution

Trailer Loading – std over-the-road trailers

• 9 docks

• Multiple loading patterns

• Safety interlocks

End of Line AGVs delivering the

complete solution

Trailer Loading

End of Line AGVs delivering the

complete solution

Automatic Battery Swapping

• Maximizes vehicle utilization

End of Line AGVs delivering the

complete solution

Automatic Battery Exchange

End of Line AGVs delivering the

complete solution

Order Fulfillment AGVs delivering

the complete solution

System Summary

• 16 Lift Deck Vehicles

• 2,200 lb capacity

• Interface with WMS

• Payback in 2 years

Distribution Center Application – Person to Goods Picking &Packing

Order Fulfillment AGVs delivering

the complete solution

Pick Pallets introduced to the picking mezzanine via 2 elevators

Order Fulfillment AGVs delivering

the complete solution

Pick Pallets picked up at elevators by AGV and delivered to 4,000 pick locations

Order Fulfillment AGVs delivering

the complete solution

Pickers walk aisles (Person to Goods Picking) and push wheeled

trolleys/carts and pick items as appropriate to build an order on the trolley.

This operation will be done by an AGV in phase 2 of the project. Automating

this operation will optimize the picking route and increase picker productivity.

Order Fulfillment AGVs delivering

the complete solution

AGVs remove empty pick pallets and trash bins from the picking area

Order Fulfillment AGVs delivering

the complete solution

Pickers push finished mixed pallet orders still on the trolley/cart to the trolley

storage area

AGVs move full trolley/carts form the picking trolley storage area to the packing

trolley storage area

Picking trolley storage area Packing trolley storage area

Order Fulfillment AGVs delivering

the complete solution

AGVs deliver empty pallets to the packing area

Order Fulfillment AGVs delivering

the complete solution

AGVs pick up packet pallets in the packing area and deliver them to the

elevators to shipping which is located below the picking mezzanine

Packed Pallet Pickup Elevators

Order Fulfillment AGVs delivering

the complete solution

AGVs move empty trolleys from the packing trolley storage area to the picking

trolley storage area

Picking trolley storage area Packing trolley storage area

What are the features of AGVs?

• Durable, expect a long service life

• Minimal infrastructure required

- Ideal for automating existing

warehouse & DC operations

• No single point of failure

• Scalable for quick expansion, reduction and even relocation

• Expect high utilization and uptime

• Use Standard Components but configured for Customer’s Application

• Very Safe: 360 degrees obstacle detection

• Typically Good ROIs for 16/5 operations

• Typically Great ROIs for 24/7 operations

What are the benefits of using AGVs?

• Reduce labor costs

• Reduced product damage

• Track product locations

• Reduce/Eliminate errors

- Right product to the right location at the right time!

• Reduce rack damage

• Increase picker productivity

• Improve safety

• Highly flexible/Easy to change

• Reduce picker strains and injuries

• Tracks system performance

© 2012 Material Handling Industry®. Copyright claimed as to audiovisual works of seminar

sessions and sound recordings of seminar sessions. All rights reserved.

For More Information:

Speaker: pat.conway@jbtc.com

Home Page: www.jbtc-agv.com

Please visit JBT Corporation at Booth 1105

MODEX 2012