Global Automotive Safety Suppliers Uses MAG300 Lifter to Automated Transfer of Laser Cut Materials

Title:
Global automotive safety supplier automates transfer of laser‑cut materials with MAG300 Lifters

Client Overview:
A leading automotive safety supplier with operations in 25 countries and a workforce of more than 70,000 employees. The company focuses on passive safety systems for vehicles, manufacturing components at scale for global automakers.

Key Stats:

• MAG300 lifters deployed: 3
• Kilometres travelled per day per AMR: 211
• Operators reallocated: 1
• Return on investment: ~2 years

The Problem

In this factory, operators manually pushed large, heavy trolleys loaded with laser‑cut parts from cutting stations to the next stage in production. The process was slow and unpredictable; trolleys weren’t collected on time, causing bottlenecks and disrupting machine utilisation. Operators were exposed to ergonomic risks from pushing heavy loads long distances. There was also little visibility into where materials were at any given moment, making tracking and management difficult.

Our Solution

Botsync implemented a fleet of three MAG300 AMRs equipped with SyncOS, along with custom‑designed trolleys. The MAG300 lifters dock directly with each trolley and transport loads autonomously between cutting stations and packaging areas. Operators no longer push the trolleys themselves; they simply load a trolley and press a button. SyncOS handles the scheduling, assigns tasks to the nearest AMR, and ensures materials arrive on time. The design reduced worker walking distances by up to nine kilometres per day and cut down on manual handling.

Key Features

Smooth Navigation in Tight Spaces

MAG300 robots operate in narrow aisles and congested areas without modifying the facility or adding markers on the floor. Sensors and safety systems keep workers and machines protected.

Quick Deployment and Training

Botsync configured the entire system and had it operational within eight weeks. SyncOS integrated with existing workflows, and operators were trained to use the system quickly thanks to an intuitive interface.

Smart Workflow Management

SyncOS coordinates tasks across multiple AMRs, ensuring continuous movement of materials and eliminating idle time. The system provides real-time visibility into each trolley’s location, improving accountability.

Impact on Operations

• Labour optimisation: One operator was reassigned to more valuable tasks, reducing the labour required for material transport.
• Reduced walking and strain: Workers no longer push heavy trolleys, cutting their walking distance by roughly nine kilometres each day and reducing fatigue and injury risk.
• Predictable throughput: Automated transfers ensure materials arrive when needed, improving machine utilisation and overall production flow.
• Clear ROI: The investment paid for itself in about two years thanks to labour savings and efficiency gains.

Conclusion

By replacing manual trolley movement with MAG300 lifters, the automotive safety supplier streamlined material transfer, improved worker safety and comfort, and achieved a significant productivity boost. The fleet’s navigation flexibility and fast deployment showcase how targeted automation can deliver rapid returns and enhance operational resilience.