Lights-Out Heavy Reel & Coil Handling for a Leading Wire Manufacturer
Leading Wire & Cable Manufacturer (Industry Benchmark Intelligent Factory), China
Results at a Glance
The Challenge
Drawn wire, wire rod, rebar coils and cable reels share a set of physical problems: each unit is heavy (often several tonnes), geometrically irregular (I-shaped reels, pancake coils, stillages), must be handled without damaging the outer wraps, and is produced continuously by machines that do not stop. Manual handling means forklifts, slings and operators moving in the path of multi-tonne rolling loads — and any mis-docking on a rewinder or gantry means lost production. This leading wire and cable manufacturer wanted to eliminate that model entirely: take finished reels off the machines, store them, and dispatch them with zero manual handling, while maintaining the gantry docking and tracking accuracy their production process demands.
The Solution
A benchmark intelligent factory was engineered around purpose-built heavy AMRs, precision gantry docking and a full 5G-connected software stack. 8-tonne heavy-duty AMRs handle the heaviest finished reels without forklifts or cranes in the traffic path. Double-pole AMRs for I-shaped wheel discs carry two reels simultaneously, or switch to single-pole mode with a 3 m lift for tall stacking — with custom sockets enabling high-precision docking with the cross-linked gantries. Laser SLAM navigation gives the AMR fleet free, map-based movement with no fixed guidewires to re-engineer when the plant layout changes. RFID positioning provides the final few millimetres of docking accuracy. A 5G plant-wide network provides millisecond-level task response across the AMR fleet and control systems. Integrated WMS/WCS/RCS coordinates every reel, every dock, every storage location and every dispatch move.
Systems Used
- 8-tonne heavy-duty AMRs
- Double-pole AMRs for I-shaped reels
- Laser SLAM navigation
- RFID precision docking
- 5G plant-wide network
- Integrated WMS/WCS/RCS
Why This Matters for South African Operations
Heavy-duty AMRs, reel-specific double-pole attachments, precision RFID docking and a 5G task layer can take the operator out of the dangerous path entirely, run 24/7, and track every coil from the rewinder to the dispatch lane. For steel producers with heavy reel handling — wire rod, rebar coil, stainless coil, tube coil — this is directly transferable technology.
Partner Technology Case Study
This project was delivered using automation technology from Allied Automation's manufacturing partners. Allied Automation supplies, integrates and supports the same technology platforms across South Africa and Africa. The results and specifications shown are those of the original deployment.
Related Case Studies
Automating a Global Zipper Manufacturer's Apparel-Component Supply Chain
Fujian Xunxing Zipper Polytron Technologies Inc. (SBS)
Reduction in inventory errors
Automating the Finished-Goods Warehouse of a Major Steel Producer
One of India's Largest Integrated Steel Producing Companies
SRM storage height
Ready to Achieve Similar Results?
Book a free assessment and let our team model what automation can deliver for your operation.