Project Overview

This case is an automated pallet transfer integrated system for the inbound logistics of CKD (Completely Knocked Down) components at a large manufacturing enterprise. The project covers the entire process including inbound unloading, material sorting, automated pallet transfer, and outbound loading, integrating core equipment and systems such as WMS (Warehouse Management System), WCS (Warehouse Control System), vision systems, DENSO robotic arms, AGV/AMR, and automated conveyor lines, building a comprehensive and highly scalable automated logistics integration platform.

Through visual data for real-time efficiency optimization, the system greatly improves work efficiency while ensuring high safety and high accuracy, effectively reducing the intensity of manual handling and the risk of workplace injuries, helping customers achieve intelligent upgrades in their logistics operations.

Challenges Faced by the Customer

Before project initiation, the customer faced the following core issues in their CKD component inbound logistics:

• Low manual pallet transfer efficiency: After CKD components arrive, goods must be transferred from shipping pallets to the factory's internal standard pallets. Manual pallet transfer is slow, labor-intensive, and prone to component damage due to improper handling.

• Difficulty ensuring data accuracy: Batch and quantity information involved in the transfer process relies on manual recording and verification, which is prone to errors and omissions, leading to discrepancies between records and actual inventory, affecting subsequent production planning.

• Mixed-flow operation complexity: Components of different sizes and packaging formats are transferred in the same area, making sorting and flow management difficult and increasing the risk of routing errors.

• Safety hazards: Heavy lifting and the intermingling of forklifts and manual operations create significant safety risks and a high rate of workplace injuries.

• Low level of informatization: Operational data across processes is scattered, lacking a unified scheduling and traceability platform, making it difficult for management to monitor work progress and efficiency in real time.

Solution and Core System Components

We custom-developed a CKD automated pallet transfer integrated system for the customer, covering the following core modules:

Inbound Module
After goods are unloaded by forklift, the inbound robot automatically handles material handling and code scanning registration. Purchase orders are automatically synchronized with the WMS system, and goods information is recorded in real time, achieving automation and informatization in the inbound process.

Material Sorting Module
After goods enter the sorting chute module, the vision system automatically identifies the size and batch information of the goods and automatically diverts them according to preset rules, ensuring that materials destined for different routes enter the corresponding pallet transfer stations.

Automated Pallet Transfer Module
DENSO robotic arms, combined with the vision system, automatically perform precise gripping and stacking of goods from shipping pallets to standard pallets. The RC9 control system ensures the accuracy and consistency of each pallet transfer operation, while the flexible line design accommodates various packaging formats.

WMS/WCS System Platform
The WMS system is responsible for rack location management, inventory data updates, electronic Kanban display, and information flow control; the WCS system handles equipment scheduling, task allocation, and alarm management. The two systems work together to achieve end-to-end data integration across the entire process.

Outbound Module
After pallet transfer, goods enter the outbound module via the cross-platform conveyor, undergo secondary verification (re-check by the vision system), and are then loaded by the outbound robot, ensuring that outbound goods fully match the order information.

Core Advantages

• High safety: Multiple protection mechanisms ensure operational safety, significantly reducing manual involvement and lowering the risk of workplace injuries.

• High accuracy: Smart verification and traceability systems ensure 100% data accuracy during the pallet transfer process, with records matching physical inventory.

• Real-time visualization: End-to-end data monitoring allows management to track work progress and efficiency in real time.

• Data chain traceability: Complete record traceability ensures the integrity and reliability of flow data for each batch and each pallet.

• High scalability: The modular system design allows flexible expansion of equipment and functional modules as business grows.

Project Results

After system implementation, the CKD component inbound logistics process achieved the following improvements:

• Pallet transfer efficiency increased by over 3 times, significantly reducing the overall cycle from unloading to inbound;

• Manual pallet transfer tasks reduced by over 80%, greatly lowering labor costs and workplace injury risks;

• Data accuracy improved to 100%, with a significant increase in record-to-inventory consistency, providing reliable data support for production planning;

• Full-process visual monitoring enables management to track work progress and efficiency in real time;

• The system has been extended to support component supply across multiple production lines, becoming a core hub in the customer's intelligent logistics system.