Background image of an industrial warehouse with forklifts moving pallets
Material Handling Automotive

40-Unit AGV Forklift Fleet Deployed Across 3-Shift Automotive DC

Modernizing material flow in a high-volume automotive parts distribution center, achieving unprecedented throughput and eliminating shift-change bottlenecks.

40 AGV Units
2.4x Throughput
35% Cost Reduction
8 Weeks Deployment

The Client Context

Tier-1 Automotive Parts Supplier

  • domain Industry Automotive
  • location_on Location China
  • aspect_ratio Facility Size 58,000 m²
  • schedule Operations 3 Shifts (24/7)

Operational Challenges

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High Incident Rate

Manual forklift traffic in tight corridors led to frequent safety incidents and product damage during peak hours.

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Labor Turnover

Maintaining a consistent workforce across three shifts was challenging, causing unpredictable throughput.

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Throughput Peaks

Inability to handle sudden surges in part requests from the assembly line, causing downstream delays.

Our Approach

Fleet Design & Dispatch Architecture

We deployed a mixed fleet of 40 Autonomous Guided Forklifts, orchestrated by our proprietary Logistics Control and Command System (LCCS). The system was designed to seamlessly integrate with their existing WMS and physical infrastructure without requiring facility modifications.

Component Specification
Hardware Fleet 40x RoboLyne F-Series AGVs
Navigation Base SLAM + Reflectors (Hybrid)
Software Stack RoboLyne LCCS Enterprise
Integration Depth Full WMS/ERP Sync (API)
Robotic forklift carrying auto parts

Business Impact

forklift 40 Active AGVs
speed 2.4x Throughput Gain
savings 35% Cost Reduction
health_and_safety 0 Incidents Post-Go-Live
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"The RoboLyne fleet didn't just replace our manual forklifts; it completely smoothed out our throughput curve. Shift changes are no longer a bottleneck, and our safety record is flawless."

Operations Director

Tier-1 Automotive Parts Supplier

Explore AGV Forklifts arrow_forward View LCCS Software
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Abstract representation of e-commerce logistics
Picking E-Commerce

Goods-to-Person Picking System Achieves 600 Orders/Hour at 99.1% Accuracy

Transforming manual order fulfillment into a high-density, high-speed automated process for a rapidly growing e-commerce hub.

600 Orders/Hour
99.1% Accuracy
3x Pick Rate
12 Weeks to Scale

The Client Context

Regional E-Commerce Fulfillment Hub

  • shopping_cart Industry E-Commerce
  • location_on Location South China
  • aspect_ratio Facility Size 32,000 m²
  • inventory_2 SKU Count 80,000+

Operational Challenges

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Accuracy Below SLA

Manual picking processes resulted in a 3% error rate, driving up reverse logistics costs and damaging customer trust.

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Scaling Issues

During promotional events, throwing more headcount at the problem yielded diminishing returns due to congestion.

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Picker Fatigue

Warehouse associates walked an average of 14km per shift, leading to severe fatigue and decreased productivity.

Our Approach

G2P System Architecture

Robotic goods-to-person picking station

We implemented a high-density Goods-to-Person (G2P) architecture. By reversing the paradigm—bringing the shelves to the operators—we eliminated unproductive walking time and dramatically improved pick accuracy through guided light systems.

System Configuration

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60x Storage AGVs
High-speed robotic base units capable of lifting 1,000kg shelving racks.
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8x Ergonomic Picking Stations
Equipped with put-to-light systems and intuitive touch interfaces.
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LCCS Dynamic Slotting
Software automatically repositions fast-moving SKUs closer to stations overnight.

Business Impact

local_shipping 600 Orders / Hour
fact_check 99.1% Pick Accuracy
bolt 3x Pick Rate Increase
directions_walk -70% Less Walking
Metric Before (Manual) After (RoboLyne G2P)
Pick Rate (UPH) 80 - 100 250 - 300+
Error Rate ~3.0% < 0.9%
Storage Density Standard Racking +40% Optimization
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"Transitioning to the Goods-to-Person model was a game-changer. We survived the Q4 holiday peak with half the temporary staff we normally hire, and our fulfillment accuracy hit an all-time high."

VP of Supply Chain

Regional E-Commerce Hub

Explore Picking Solutions arrow_forward View Storage AGVs