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Automotive Assembly Line in Thailand
Line-Side AGV & Small Parts Pick-to-Light Integrated Storage Project

Key Results
Space Optimization: Line-Side Storage Efficiency Increased by 73%
Quality Control: Mis-assembly Rate Dropped to < 0.01%
Production Speed: Assembly Takt Time Improved by 45%

Project Pain Points

The project covers a 1,200㎡ line-side storage area of an automotive assembly workshop in the Amata City Rayong Industrial Estate, Rayong. Managing over 2,300 SKUs of components for engine and chassis assemblies, the workshop suffered from severely restricted line-side storage space, leading to disorganized and chaotic parts stacking on-site. Furthermore, manual parts retrieval and verification were highly inefficient. Frequent assembly errors and omissions directly resulted in vehicle defects, heavily bottlenecking the overall production takt time of the assembly line.

Core Solutions

■Custom Mobile Automation: Deployed 107 custom multi-lift assembly AGVs to completely replace the legacy slat-chain conveyor line systems.
■Precision Picking System: Equipped small hardware and auxiliary materials with PTL (Pick-to-Light) smart racking systems to streamline the manual picking process.
■JIT Production Synchronization: Integrated our "Tianshu" WCS with the vehicle master production schedule to enable seamless Just-In-Time (JIT) parts delivery.
■Lean Deployment: Achieved full system integration across the workflow without requiring heavy civil modifications or major warehouse construction.

Business Value Delivered

■Highly Efficient Space Utilization: Boosted line-side warehouse space utilization by 73%. The existing footprint now fully supports line-side buffering for the entire spectrum of SKUs without needing any facility expansions.
■Upgraded Assembly Quality: Successfully brought the part mis-assembly rate down below 0.01%, suppressing product defect rates right from the logistics stage to ensure high-quality vehicle rollouts.
■Accelerated Production Takt: Compressed the vehicle production line takt time to yield a 45% increase in efficiency. Automated, unmanned JIT delivery has completely replaced manual material fetching, empowering the facility to seamlessly match mass-production demands.

Automotive Parts in Thailand
Racking System Reuse & Piece-Picking Intelligent Retrofit Project

Key Results
Picking Efficiency Breakthrough: Piece-Picking Efficiency Increased by 60%
Cost Optimization: Retrofit Cost Only 15% of a New-Build Warehouse
Quality Assurance: Picking & Shipping Errors Drastically Reduced

Project Pain Points

The automotive parts central warehouse covers an area of 1,600㎡ and is located in the WHA Eastern Seaboard Industrial Estate, Chonburi. Managing over 3,100 SKUs of diverse auto parts, the facility relied entirely on manual paper-slip verification for piece-picking, leading to frequent picking and shipping errors that constantly disrupted the vehicle assembly timeline. Although the original racking infrastructure was in excellent condition, the enterprise enforced a highly stringent budget constraint and strictly ruled out any large-scale demolition or rebuilding.

Core Solutions

■In-Situ PTL Integration: Installed a digital Pick-to-Light (PTL) system directly onto the existing legacy racking structure to guide operators visually during piece-picking.
■AGV-Driven Transfer: Deployed latent AGVs to seamlessly handle full-pallet transfers from the central storage warehouse to the line-side production zones.
■Lightweight Software Deployment: Configured a lightweight version of our "Tianshu" WMS to interface seamlessly with the automaker's existing ERP system, enabling rapid go-live execution.

Business Value Delivered

■Surge in Picking Efficiency: Piece-picking throughput increased by 60%. The pick-by-light visual guidance drastically dropped manual verification overheads and fundamentally eliminated mis-picking and mis-shipping issues.
■Highly Controlled Retrofit Costs: By fully maximizing and reusing the existing racking infrastructure, the project achieved a short execution cycle and low capital commitment—with the overall cost wrapping up at just 15% of constructing a new intelligent warehouse.
■Smooth System Adaptation: Seamlessly interfaced with the legacy ERP software without necessitating a complete overhaul of the existing inventory workflows. This achieved rapid time-to-value while perfectly syncing with the automaker's daily operational rhythm.

Cross-Workshop Material Connectivity in Thailand
Three Major Manufacturing Workshops Intelligent Storage Project

Key Results
Turnover Optimization: Material Turnover Efficiency Increased by 70%
Fleet Reduction: Manual Forklift Usage Reduced by 75%
Traffic Management: Factory Logistics Congestion Reduced to Zero

Project Pain Points

The factory's supporting storage facilities cover a total area of 3,800㎡ within the Thai-Chinese Rayong Industrial Zone, Rayong, serving three main process workshops: Stamping, Welding, and Final Assembly. Single steel billets in the stamping shop weigh up to 2.8 tons, and their semi-finished products suffered from highly disorganized temporary stacking. Furthermore, cross-workshop material transfers relied entirely on manual forklifts, causing severe, year-round traffic congestion along the factory thoroughfares and significantly dragging down overall material turnover efficiency.

Core Solutions

■Diverse AGV Fleet Deployment: Deployed 268 mobile robots, including medium-duty latent AGVs and reach-type forklift AGVs, to handle varied material profiles.
■Heavy-Duty Automation: Paired the system with a dual-station stacker crane configuration specifically designed to handle the secure storage and retrieval of heavy-load stamping steel billets.
■Hybrid Warehouse Topology: Designed an integrated layout combining a centralized AS/RS with distributed line-side buffering warehouses across the facility.
■Unified Software Centralization: Utilized the central WMS system to globally orchestrate and synchronize inventory data across the entire factory footprint.

Business Value Delivered

■End-to-End Interconnection: Achieved seamless full-loop material and data connectivity across the Stamping, Welding, and Final Assembly workshops, creating a single source of truth for inventory and breaking down operational data silos.
■Logistics Traffic Eliminated: Slashed manual forklift usage by 75%. Replacing chaotic manual transfers with disciplined, algorithmic AGV dispatching has completely cleared congestion within factory transit aisles.
■Accelerated Turnover Efficiency: Boosted total component turnover efficiency by 70%. Standardizing the storage and transport of heavy materials has established a highly reliable logistics backbone to support steady mass production across all workshops.

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