A leading international tire manufacturer sought to optimise its large-scale logistics operations across a multi-workshop production site. Managing the movement of heavy transport vehicles, materials, and components across multiple facilities had become increasingly complex and labour-intensive.

To address these challenges, the manufacturer needed to implement a comprehensive intelligent logistics automation solution powered by advanced Forklift AGVs and real-time scheduling systems.

The client’s production site spanned several specialised workshops handling a range of materials and semi-finished products. Transporting large and heavy loads required significant manual effort and constant coordination between departments.

This created several ongoing issues:

Labour-intensive operations requiring large staffing levels and shift-based scheduling.

High risk of inefficiencies and errors in manual transport processes.

Inconsistent logistics coordination between workshops.

Limited data visibility for real-time operational management.

The manufacturer needed a scalable, automated transport system capable of operating continuously while maintaining high safety and efficiency standards.

A custom designed and built integration of an intelligent Forklift AGV system, incorporating advanced navigation and scheduling technologies for fully automated logistics handling.

The project included:

146 Forklift AGVs selected and configured for various load types and operational needs.

1 intelligent scheduling and control system, ensuring optimal routing and resource allocation.

50 charging stations distributed strategically to support continuous, uninterrupted operation.

The system was fully aligned with the client’s existing WMS and digital infrastructure, enabling a seamless transition to intelligent, data-driven logistics.

The automation initiative delivered measurable operational improvements across all key metrics:

Maximum Efficiency:
Integrated with the client’s management systems, enabling real-time monitoring and dynamic control to optimise operational flow.

Stability and Flexibility:
The system met the demands of 24/7 continuous production, providing consistent reliability across all workshops.

Cost Reduction:
Autonomous operation reduced labour intensity and logistics costs while minimising human error and downtime.

Safe Production:
Built-in safety features — including laser detection, automatic stop functions, and audible alerts — ensured secure operations in high-traffic production zones.

The result was a fully modernised logistics framework that improved productivity, safety, and cost-efficiency across the manufacturer’s facility.

Ready to Upgrade Your Manufacturing Operations ?

Allied Automation continues to support manufacturing enterprises seeking to modernise their logistics systems through automation, intelligent scheduling, and seamless data integration.

If your organisation is ready to streamline operations, reduce labour intensity, and achieve safer, smarter logistics — Allied Automations expertise can help guide your next transformation. Contact us today to find out how.