Case study:
How an automation project coordinator implemented 15 Autonomous Mobile Robots and reduced inventory by €3 million
Assigned expert
Automation project coordinator
Challenge
A major automotive manufacturing plant needed to improve its internal logistics, reduce inventory across the material flow and prepare production for future growth without increasing headcount.
Over a period of more than two years, our expert gradually moved from production planning into leading a strategic manufacturing and logistics automation project, taking responsibility for solution design, technology selection and full implementation.
The company was looking for a way to automate logistics processes, simplify material flow management and increase overall operational efficiency.
Key challenges included:
- high inventory levels across production operations,
- manual logistics processes with limited efficiency,
- increasing demands on internal logistics,
- the need to automate material flow management,
- selecting the right technology and implementation partner for logistics automation.
GQ solution
As the project evolved, the client continuously expanded the scope of his responsibilities. What started as a production planning assignment developed into leading a strategic automation initiative covering both manufacturing and internal logistics.
His role was to design the automation concept, prepare the business case, select the most suitable technologies and ensure successful implementation.
Key activities included:
- designing and implementing an electronic Kanban system,
- optimizing supply chain processes and material flow,
- reducing inventory by approximately €3 million,
- selecting the technology and supplier for the Autonomous Mobile Robots (AMR) solution,
- leading the implementation of 15 AMRs from concept through go-live,
- coordinating suppliers, internal teams and implementation activities,
- developing the concept for an Automatic Planning Board (APB) to support automated production planning.
Result
- inventory reduction of approximately €3 million,
- implementation of an electronic Kanban system across the material flow,
- successful deployment of 15 Autonomous Mobile Robots (AMR) within internal logistics operations,
- reduction of approximately 9 logistics positions through automation,
- return on investment for the AMR project in approximately 1.5 years,
- a simplified and more efficient material flow,
- readiness for future production growth without the need for significant workforce expansion.
Automation delivers results only when it improves the entire process
This project demonstrated that well-designed manufacturing and logistics automation can significantly reduce inventory, improve operational efficiency and prepare a production facility for future growth without the need for extensive hiring.
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