Results of Step 1

Implementation Results

By advancing smart-factory capabilities, we delivered measurable outcomes in both logistics efficiency and shop-floor productivity.
Specifically, we achieved a 14.8% improvement in operational efficiency, a 23.5% reduction in warehouse floor space, and a 30% reduction in tow tractors.

Enabling Flexible, High-Efficiency Operations Through Smart-Factorization

As the wave of smart manufacturing spreads worldwide, Intersect leveraged its strong system-integration capabilities to build a smart logistics solution for the automotive parts industry—combining innovative hardware with tightly coupled system connectivity.
Through advanced integration of hardware such as AMRs (Autonomous Mobile Robots), scan gates, lifts, and stacking equipment with a WES (Warehouse Execution System) and a WMS (Warehouse Management System), the solution automates logistics across the entire workflow—from receiving and vertical transfer to put-away and outbound shipping. This drives both cost reduction and efficiency gains while offering an industry-standard model that can be applied across other companies and sites. 

[Hardware Deployment Results]

・AMR (Autonomous Mobile Robot):transport speed 1.5 m/s
・Automated scan gate:processing time 9.9 seconds per pass, accuracy 99.99%
・Lift:42 upward cycles/hour, 46 downward cycles/hour
・Stacking machine (pallet stacker):90 cycles/hour 

[System Deployment Results]

1. WMS (Warehouse Management System) — the core of inventory management
Overall control: updates inventory status in real time and manages FIFO.
Automatic instruction generation: automatically creates put-away, picking, and dispatch/shipping instructions and sends them to the WES, enabling automated instruction creation.
2. WES (Warehouse Execution System) — equipment control
Equipment integration: centrally manages hardware such as AMRs, lifts, and pallet stackers; automatically decomposes transport tasks and issues execution commands to each endpoint.
Equipment monitoring: monitors operating status in real time, detects abnormalities immediately, and triggers alerts to ensure timely execution of instructions.
Efficiency management: collects work results in real time, generates KPI reports (e.g., transport efficiency and equipment utilization), and identifies continuous improvement opportunities.
By maintaining shop-floor flexibility, the solution achieves both labor savings and high efficiency.
We provided end-to-end support—from smart-factory concept and design through technology selection and operational stabilization.

[Next Steps]

1.Deepen AMR know-how and improve utilization to reduce the number of units, and redeploy them for parts supply to future production processes.
2.To enable unmanned picking operations, further improve workflows and promote standardization of carts and bins/boxes so they can support automation.