Chery Automobile Co. and ForwardX Robotics, a provider of autonomous mobile robots (AMRs), have announced the ideployment of an AMR solution that handles line-side replenishment of materials at Chery’s Super One Factory in Qingdao, China.
Established in 2023, Chery Super Factory is an automobile manufacturing plant with a focus on integrating advanced technologies and realizing digital transformation. With an annual production capacity of 300,000 vehicles and 200,000 KD units, the factory aims to be at the forefront of business integration, smart supply chain management, and a robust logistics ecosystem, the companies added.
Vision-Based AMRs
Chery is using vision-based AMRs for automated material movement in the assembly workshop. In this first stage of deployment, as the ForwardX announcement explained, more than 100 AMRs have been integrated with the factory’s Logistics Execution Systems (LES) software to enable unmanned material movement across various assembly lines.
In the post-installation line, ForwardX’s Flex 300-L AMRs transport materials from the staging area to designated workstations after barcode verification. The AMRs dock with the racks and utilize their advanced vision systems to execute secure material transportation.
Autonomous Tugger AMRs
In the interior line and door line processes, ForwadX’s Lynx U1000 autonomous tugger AMRs integrate into the SPS system and transport materials from the staging area to the line-side workstations. The AMRs navigate to the material staging area with empty racks, and pickers use light indicators as guidance for picking and matching. Once the AMR reaches the unloading point on the line side, the full racks are automatically unloaded. After completing the material delivery, the AMRs independently mount empty racks at the rack collection point and return.
In the chassis line process, Chery Super Factory prioritizes sustainability by reusing old racks and employing ForwardX’s Apex 2000 autonomous forklifts in specific processes, promoting an eco-friendly approach and reducing waste. An overview video of the AMR implementation at the Super Factory can be seen here on YouTube.
Since implementing ForwardX Robotics’ smart automotive manufacturing solution, the companies added, the Chery Super Factory has successfully lowered the logistics cost per vehicle by an 10%. Moreover, the system keeps the line-side over-supply rate below 15% and the assembly error rate of less than two per-thousand vehicles. By effectively managing inventory levels and eliminating assembly errors, the new distribution process minimizes the possibility of production line disruptions, resulting in a 200% increase in efficiency and a significant reduction in operational costs.
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