An engineer's dream: Create a manufacturing facility from the ground up. The team at a major automotive supplier was able to do just that when they cherry-picked the elements for an advanced lean manufacturing facility. They chose a simple and adaptable automatic guided vehicle (AGV) system.

The plant provides in-sequence, just-in-time (JIT) delivery of front-end modules, cockpit systems, fuel storage systems, and climate systems for an automaker's assembly plant. This operation was starting up in a new building with new equipment, so plant layout, assembly systems, auxiliary units and materials handling and logistics could all be strategically planned and selected from proven technologies.

Sixteen two-section AGVs, with aluminum frame chassis with drive train and path-following sensors and roll-on/roll-off racks, keep instrument panel and radiator functions running to sequenced build and JIT schedules. They feature RFID-monitored traffic control systems to maintain a smooth flow of parts and vehicles.

The AGVs carry racks that are constructed with a series of plastic coated steel pipes, joints and hardware accessories that allow users to design and fabricate structures custom matched to application needs.

Each vehicle has a mounted control unit that provides up to 10 programmable routes that can be stored and recalled by a single button. Specific course commands are activated via magnetic signals detected by the chassis mounted sensor.

Another critical element is the application of RFID tags along the guidance paths. Each AGV has an RF sensor and radio transmitter to identify the unit's position to prevent collisions and congestion.

There's also a schedule for rotating and charging AGV batteries, which maximizes battery life and improves performance.

A cost-effective and adaptive AGV system that delivers sequenced components to assembly stations makes this a focused factory.

Creform Corporation 800-839-8823 www.creform.com