The automation of inbound and outbound logistics flows of materials is an exciting challenge for companies aiming to achieve maximum efficiency in their operations. For Synersight, the automation process begins with a clear goal: to improve efficiency, increase production, and reduce costs. In this context, discover how Gestamp Aveiro, a leading company in the automotive industry, takes a significant step towards efficiency and quality by automating its production and logistics flows, redefining container management, and setting a new standard in internal operational optimization
In the highly competitive world of the automotive industry, the pursuit of efficiency and process improvement is essential. In 2022, Gestamp Aveiro, a leading company in this sector, decides to enhance the efficiency of its internal logistics operations by taking a significant step to create a flow automation project that has redefined the way they manage containers between facilities. This project not only addresses complex internal logistics challenges but also incorporates advanced technologies to ensure efficiency and safety.
At Synersight, we are a global company providing comprehensive services and projects. We offer our clients solutions to maximize the efficiency of their processes through our sector-specific knowledge and the application of technology with a different and personalized approach.
THE CHALLENGE
The main objective of this ambitious project was to automate production and logistics flows, significantly improving operational efficiency and product quality. Previously, all transportation was carried out using two trucks in three shifts and a forklift.
“The need for this project arose from the intention to reduce existing logistics costs in our factory with the transportation of the entire final product between our production facility and the logistics warehouse,” says Luis Rocha, LEAN GAV Coordinator.
To meet this goal, an automated transport system based on two CMV25 model AGVs has been implemented, connecting the production facility and the logistics warehouse through an outdoor circuit.
One notable feature of this project is the outdoor section that connects the critical areas of the two warehouses. This circuit is a rarity in the industry, as few manufacturers of industrial AGVs venture into outdoor operations. In addition, Synersight‘s CMV25 has to defy gravity with a 14% slope and pull loads of up to 10 tons, composed of a convoy of a maximum of 10 rolling bases.
OPERATIONS MANAGEMENT AND SAFETY
Safety and efficiency are priorities in this project. Electrical panels have been installed in the production and logistics warehouses to manage various functions, such as validations for the actuation of the automation in production and logistics, changing the operating mode for one or two AGVs, and a button to return to the initial state. In addition, additional safety systems managed automatically by the AGVs have been implemented, such as photocells to verify the position and opening of doors and barriers, traffic lights, and rotating beacons at intersections with trucks. These devices ensure that the AGVs move safely and efficiently in areas of potential interference.
The coordination of all these operations is achieved through the fleet management software VSYSTEMS, developed entirely by Synersight. This software provides a user-friendly environment, allowing the programming and configuration of AGV circuit functionalities. It offers different levels of access and configuration capability, adapting to GESTAMP‘s specific needs and ensuring total control over the system.
POSITIVE OUTCOME
GESTAMP Aveiro‘s production and logistics flow automation project is a standout example of how innovation and vision can transform efficiency and safety in the automotive industry.
GESTAMP has demonstrated that through intelligent automation and the incorporation of advanced technologies, it is possible to overcome complex logistical challenges and increase productivity without compromising safety. “The automation of this flow with the implementation of AGVs has replaced the use of 2 trucks, 1 driver per shift (3 per day), and 1 forklift, making it economically more interesting. Despite the technology present in this new system, its use is very simple and logical for everyone involved in the system. Another important aspect has been the ease of amortization, as the entire investment can be amortized in a very short time,” says Luis Rocha.
This case demonstrates that intelligent automation can not only improve efficiency but also drive sustainability in vehicle manufacturing.
