Ashok Leyland Improved ROI by 70%

Title:
Ashok Leyland Improved ROI by 70%

Company Overview:
Ashok Leyland, headquartered in Chennai, is a leading Indian multinational automotive manufacturer. It is India’s second-largest commercial vehicle maker, the world’s third-largest bus manufacturer, and the tenth-largest truck manufacturer. The company operates seven factories across India and two overseas plants in the UAE and the UK.

Key Stats:

• MAG 300 AMRs: 3 units
• Engines produced per hour: 15
• Operating hours: 24/7
• Return on investment: 2.5 years

The Problem

The engine production workflow required operators to manually push engines weighing up to 400 kg from the test cell (where engines undergo rigorous performance and safety testing) to the dressing area for final assembly.

This involved multiple operators and introduced ergonomic strain and risk of injury. Engines were not always collected promptly once testing was completed, causing bottlenecks at the dressing area and delaying downstream processes. The company needed a reliable automation solution to move engines safely, consistently, and without operational delays.

Our Solution

Fleet of 3 MAG300 Lifters to Automate Engine Transfer

Botsync deployed three MAG300 Lifter AMRs along with a custom call-panel system. Operators confirm when an engine is ready using the panel, and SyncOS automatically assigns the most suitable AMR for pickup and transport to the dressing area.

At the same time, SyncOS sends an empty trolley back to the pickup point to ensure operators can keep working continuously with no downtime.

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Key Features

MAG Fleet Integrated with Call Panels
The SyncOS Integrator links MAG300 lifters with call panels across the factory so operators can trigger AMR tasks intuitively.

Agile and Easily Configurable
MAG300 robots navigate without tape or QR codes, making layout changes simple and allowing new workflows to be added without infrastructure modifications.

Intuitive User Interface
SyncOS enables users to create tasks and resolve errors quickly, without needing technician support.

Remote Support Integration
Botsync’s remote-monitoring system allows the team to detect issues proactively and maintain uptime above 99%.

Impact on Operations

• Reduced engine waiting time by around 1%, increasing monthly output by 2–3 engines
• Improved overall safety and lowered risk of engine-related accidents
• Reduced physical strain on operators, creating a healthier and safer work environment

Conclusion

The introduction of three MAG300 lifters significantly improved Ashok Leyland’s engine-transportation workflow. Automation reduced delays, improved productivity and safety, and eased physical load on workers. The solution also proved scalable and delivered an attractive return on investment of approximately 2.5 years.