Intelligent Scheduling System and AGV Robots to Achieve 60% Increase in Warehousing Efficiency, and Zero Injury Breakthroughs

New energy high-tech enterprises focusing on lithium batteries, energy storage system R&D and production are facing challenges. With the expansion of production capacity and process upgrades, their warehouses are experiencing low material handling efficiency, a high degree of artificial dependence, insufficient use of storage capacity, and other issues. The traditional manual handling mode is prevalent in areas of high work intensity, slow response speed, and in shelves and stacking areas, such as the co-management of pain points. To promote the intelligent transformation of warehousing, the enterprise introduced 3 sets of AiTEN AS15 handling robots and 2 sets of APe15 handling robots, combined with the intelligent scheduling system and warehouse management system, to realise the automation of the whole process from warehousing to warehousing, and to improve the safety of the operation and the standardisation of management.

Core Highlights

1. Deep integration of the intelligent dispatching system

• Based on task priority and real-time status of AGV (power, position, load), dynamically plan the optimal path to achieve multi-vehicle co-avoidance;
• Supports manually sending tasks through the tablet with one key, and the system automatically disassembles it into the command chain of ‘pick-up-carrying-placing’, which reduces human intervention.

2. Upgrade of warehouse management refinement

• Shelving area adopts the mode of ‘warehouse code + dynamic allocation’, and the system records the location of materials and inventory status in real time.
• Inventory data is connected with the MES system to realise the visualisation of the whole chain of ‘in-store - storage - out-store’.

3. Human-computer interaction and safety protection

• The interface of the operation panel is simple, supporting real-time tracking of task status and abnormal alarms (e.g., full warehouse, AGV failure).
• AGVs are equipped with laser obstacle avoidance, emergency stop buttons, and sound and light warnings, ensuring safety protection for the whole scenario of ‘human-vehicle-cargo’. 

Business Process and Implementation Effect

1. AGV Staging Area → Warehouse Warehousing Process Details: ‍

Incoming materials are manually placed in the staging area staging space, and the type of warehousing is selected through the flatbed (shelf/floor stacking);

Scheduling system automatically allocates models: AS15 is responsible for the shelf area (accurately lifted to the 1600mm storage space), and Ape15 is responsible for the floor stacking area.

Warehouse management system dynamically allocates the space, and the AGVs automatically update inventory data after completing the placement. The stock management system dynamically allocates empty spaces and automatically updates the stock data after the AGVs are placed.

Comparison of Effect:

60% increase in the efficiency of warehousing;

increase in the utilisation rate of shelf capacity from 75% to 95%, and a 40% reduction in the waste of space in the floor stacking area.

2. Warehouse → Outbound Staging Area Process Details:

Manually select outbound materials through the tablet, and the system automatically searches the warehouse and generates tasks.

AGVs pick up the goods according to the optimal path, transport them to the outbound staging area, and synchronously trigger the inventory deduction.

Outbound tasks support batch dispatch, and multiple AGVs work together to avoid path congestion.

Comparison of Effects:

The response time of outbound storage is shortened from 30 minutes to 8 minutes.

The wrong/missing rate is reduced from 1.2% to 0.1%, and the accuracy rate of outbound storage reaches 99.9%.

Project Results and Benefits

1. Efficiency and Cost Optimisation

• Reduction of 8 porters;
• 55% improvement in handling efficiency;
• Shortening of the equipment payback cycle to 1.8 years.

2. Management Upgrade

• 100% accuracy of inventory position, 90% reduction of inventory counting time;
• Real-time monitoring of AGV operation status and inventory dynamics through visualised Kanban boards, 40% increase in management decision-making efficiency.

3. Safety and Sustainability

• 100% reduction in the rate of industrial accidents, achieving ‘zero human handling damage’; 

Summary

By deploying the combination of AS15 and Ape15 dual-vehicle AGVs and an intelligent management system, the enterprise has built a ‘flexible handling + digital control’ system suitable for new energy warehousing scenarios, achieving a triple breakthrough in efficiency, safety and cost. The project not only solves the operational bottleneck of traditional warehouses but also provides support for lean production through data-driven methods, and becomes a model for the intelligent transformation of warehousing in the new energy industry. In the future, we can expand the scale of AGV clusters to further advance towards the goal of ‘unmanned warehouse’.

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.