Case Studies
WHIRLPOOL
Our AGV system streamlines Whirlpool’s washer production by transporting key components from shipping to assembly with precision. The fleet operates seamlessly alongside existing systems, optimizing material flow and plant efficiency.
STELLANTIS
A fleet of 100 AGVs drives Stellantis’ electric vehicle battery production, moving heavy battery packs through complex assembly and testing. Intelligent traffic coordination ensures continuous flow and rapid rerouting for maximum uptime.
JOHN DEERE
At John Deere’s utility tractor plant, 100 AGVs automate transport across three buildings, advancing tractors through every assembly stage. Integrated with MES software, the system boosts production efficiency and empowers on-site team control.
WHIRLPOOL
Optimizing AGV Logistics for Whirlpool’s Clyde, Ohio Plant
Whirlpool’s Ohio manufacturing facility is dedicated to producing washing machines. IDC implemented a comprehensive AGV solution to streamline material handling. The plant features a central conveyor system, and our AGVs efficiently transport essential components — such as door panels, consoles, and other parts — from shipping docks directly to various points along the production line.
Key highlights of the project include:
COMPLEX ROUTING
The system handled 12 distinct material types, each requiring separate pickup and drop-off points, essentially creating a network of overlapping routes. This required meticulous coordination and communication.
DIVERSE FLEET & CUSTOMIZATION
The project involved deploying around 26 AGVs, each tailored with specific tools or conveyance systems to meet the unique needs of the production line. Each AGV had a towing capacity of up to 5,000 pounds, allowing for efficient material transport.
SEAMLESS INTEGRATION
Our AGVs were integrated with other conveyance systems, ensuring no overlap or traffic conflicts. This collaboration enabled smooth, synchronized operations across the entire fleet.
SCALABLE OPERATIONS
With the addition of our AGVs, the facility now operates a fleet of nearly 60 vehicles, providing a highly flexible and scalable logistics solution.
In summary, this AGV implementation significantly enhanced the efficiency and reliability of Whirlpool’s production line, ensuring the timely delivery of materials and seamless integration within a complex operational environment.
STELLANTIS EV INITIATIVE
AGV-Driven Battery Assembly
In support of Stellantis’ electric vehicle revolution, our innovative solution centers on advanced AGVs. At the heart of the process is our fleet of 100 AGVs, each with a 2,000-pound capacity, which seamlessly transport batteries through multiple assembly stations.
While the Sterling Heights facility manages the intricate coordination and sequencing, our AGVs navigate through the line, ensuring batteries receive their respective assembly steps — like lug installation and harness connections.
A unique aspect is our traffic coordination: if any issues arise during testing — like electrical or leak tests — AGVs can be rerouted to dedicated repair areas. This ensures a smooth and efficient workflow.
It’s important to note that while we focus on the conveyance with our AGVs, the assembly line integration is handled by our partners, highlighting our specialization in AGV technology.
JOHN DEERE
Utility Tractor Assembly
At the Grovetown, Georgia facility, we’ve deployed around 1 00 AGVs to support John Deere’s utility tractors and backhoe attachment assembly lines. The AGVs are strategically distributed across three buildings, moving efficiently from station to station, ensuring that each component is added seamlessly.
For the smaller-duty models, we utilize AGVs with a 7,000-pound capacity, while the larger duty models benefit from 12,000-pound capacity AGVs. The system is designed with straightforward path planning, essentially forming a large loop from one station to the next.
A key highlight of this implementation is the seamless integration with John Deere’s MES system. As operators complete tasks at each station, they swipe their badges, signaling completion. This triggers the AGV to move forward to the next station, ensuring smooth coordination and minimal downtime.
Our collaboration with John Deere goes beyond just providing equipment. We offer on-site training and support, empowering John Deere’s team to take ownership of the system. This approach not only fosters a sense of partnership but also ensures that John Deere can adapt and evolve their assembly lines without unnecessary hurdles.
This collaborative and customer-centric philosophy sets us apart in the industry, ensuring that our systems are not just efficient but also truly integrated into the customer’s workflow.
