From Manual to Unmanned Handling: MP10S + TP30 Handling Robots for Synergistic Applications in the Manufacturing Industry

A large industrial manufacturing company in Shanghai is an important branch in China of a leading global industrial group headquartered in Germany, which is committed to combining German advanced industrial manufacturing technology with Chinese market demand and promoting localised production and operation. With the opening of the new headquarters in Shanghai in 2024 and the expansion of production lines, the company improved the efficiency of production logistics and reduced operating costs, the customer introduced AiTEN robots intelligent logistics handling solutions, to create an efficient and accurate on-site intelligent logistics system.

Core Pain Points

1. High fluctuation of manual handling efficiency and high labour cost;

2. In complex cross-floor collaboration, material flow across floors relies on manual call lifts;

3. Many management blind spots, and lagging inventory data updates.

Target Demand

Through intelligent upgrading, realise full-process automated handling, and build a highly efficient, accurate and scalable intelligent logistics system.

After receiving the customer's demand, AiTEN tailored the ‘robot + system’ personalised intelligent logistics handling solution to the customer's actual scene and needs after a careful site survey.

Project Highlights

1. Technical programme innovation

Hardware Configuration: MP10S customised robot, heightened frame design, adapted to narrow aisle scenarios, space utilisation rate increased by 40%;

System integration:

• RDS Intelligent Dispatch System: Advanced algorithms are used to analyse and optimise logistics data in real-time, achieving optimal path planning for material sorting and distribution, improving operational efficiency and accuracy, and increasing collaborative efficiency by 65%;
• LMS warehouse management system: real-time tracking of warehouse status, mismatch rate reduced to 0.1%;
• MES/ERP in-depth docking: work orders drive logistics tasks, realising closed-loop production and logistics data.

2. Scenario-based function upgrade

Intelligent obstacle avoidance and abnormality processing:

• LIDAR + vision fusion navigation, collision avoidance rate 100%;
• Ai automatically identifies incoming/scanning anomalies, increasing disposal efficiency by 80%.

Cross-floor seamless handling:

• The robot calls the lift autonomously, and the response time for cross-regional handling is shortened to 10 seconds.

Project Results and Benefits

1. Efficiency and cost optimisation

• Reduction of 10 porters, 30% reduction in manual handling costs;
• Order response time improved by 2.75 times;
• 71% reduction in energy consumption for lift waiting.

2. Management Upgrade

Visualisation of the whole process: digital twin kanban boards monitor the logistics status in real-time, increasing the efficiency of abnormal traceability by 90%;

Summary

The project cracks the traditional manufacturing logistics pain points through the deep integration of ‘robot cluster + intelligent algorithm + digital twin’.

The programme takes AiTEN's ‘MP10S handling robot and TP30 submerged jacking type handling robot’ as the selected products, and puts into use a total of 6 sets of MP10S and 4 sets of TP30 handling robots in 2024, and will add 6 sets of handling robots in three new phases of the project this year, for a total of 16 sets of handling robots. Supplemented by AiTEN's RDS intelligent scheduling system and LMS warehouse management system, thus realising the whole process of automated handling of products from raw materials online to finished products packed into warehouses, and shortening the ROI cycle to 2.3 years.

This project not only provides a reference path for the transformation of intelligent logistics for many manufacturing industries but also lays a solid foundation for the customer to subsequently expand the application of AIoT technology and deepen the layout of intelligent manufacturing.

For businesses facing similar challenges, AiTEN’s handling solution offers a proven path to operational excellence. Contact AiTEN today to learn how our innovative robotics and intelligent systems can transform your material handling processes.