NEWS

Currently, in the wave of intelligent manufacturing transformation and upgrading, the traditional excavator manufacturing industry is also actively exploring digital and intelligent development, but the application of automated three-dimensional warehousing is still in its infancy. Recently, the intelligent storage project for key components of a certain excavator factory, built by Zhongjian Intelligence, has been successfully implemented. With intelligent technology, it solves the pain points of traditional warehousing and provides a replicable practical model for the large-scale promotion of automated warehousing in the industry. The demonstration effect is significant.

Project Introduction

The client is a leading enterprise in the excavator industry and even the entire construction machinery industry. The planned renovation of the excavator factory project covers an area of approximately 2500 square meters with a floor height of 12 meters, focusing on solving the efficient storage and flow needs of 7 key purchased components such as engines, main valves, main pumps, and rotary motors. Zhongjian Intelligent deeply understands the pain points and needs of customers, such as insufficient storage space and easy errors due to manual sorting. It tailors a pallet stacker crane elevated storage system+AGV conveying and handling system for them. Through an intelligent warehousing management and scheduling system, it realizes the full process automation and intelligent management of materials from warehousing, storage to outbound, and then to connecting with the production end, helping customers create efficient and accurate "unmanned" warehousing scenarios and reduce overall warehousing operating costs.

Customer benefits

After the project was implemented, the customer's warehousing efficiency and floor area efficiency achieved a qualitative leap:

Sharp reduction in labor costs: The original warehouse required 30-40 people to manually operate the handling and sorting, but now only 4-6 people are needed to be responsible for manual unpacking, lifting to pallets, monitoring systems, and other work, saving nearly 3 million yuan in annual operating costs;   

Space intensive utilization: The three-dimensional shelf design fully exploits the 12 meter high space, increasing storage density by more than three times compared to traditional flat warehouses, completely solving the historical problem of "insufficient space and disorderly stacking of goods".

Comprehensive efficiency upgrade: The inbound and outbound efficiency is 360 pallets per day, which can meet the full production status of 90 units per day; The error rate of spare parts storage is almost zero, inventory is visualized in real-time, and decision-making is more scientific.

Project difficulties and pain points

The project is facing three core challenges in its progress, which are also common challenges for the promotion of automated warehousing in the mechanical manufacturing industry:

Material diversity: 8 types of components have significant differences in specifications and weight, requiring adaptation to 12 customized pallets, balancing flexible storage and precise positioning;

Process complexity: From unpacking, hoisting to warehousing, searching, sorting, and distribution during outbound, the process is cumbersome. Traditional manual searching and picking are prone to errors and need to meet the production line's 7-minute cycle time requirement per unit;

High stability requirements: The core components have high precision and need to avoid collisions during transportation. The equipment positioning error needs to be controlled within ± 5mm, while ensuring a daily throughput efficiency of 360 pallets.

Solution

After fully understanding customer needs and production process characteristics, Zhongjian Intelligence broke through with a dual engine of "customization+intelligence":

Customized pallet storage system: Design two specifications of three-dimensional shelves (a total of 4616 storage positions) and 12 types of pallets to accommodate the storage of accessories of different specifications and sizes. Equipped with 5 double extension single station stacker cranes to achieve high-density storage and retrieval of three-dimensional shelves, with a positioning accuracy of ≤± 5mm.

AGV+conveyor seamless connection: Through the collaborative operation of chain conveyors, lifting conveyors and other equipment with AGV, a "goods to people" intelligent distribution network is built, with zero delay in material transfer.

Intelligent Brain - WMS/WCS Intelligent Management System: The WMS system realizes intelligent inventory scheduling, automatic inventory counting, warning management, and real-time tracking of material status; The WCS system accurately schedules equipment tasks to ensure efficient and coordinated operation of multiple tunnels and devices; Build a digital twin model for real-time monitoring of equipment status, traffic data, and predicting operational needs.

From "manual stacking" to "unmanned warehousing", Zhongjian Intelligence once again proves the trend and efficiency of automated warehousing in the mechanical manufacturing industry through the excavator factory's warehousing project. In the future, Zhongjian Intelligence will continuously optimize and upgrade the overall service level and comprehensive strength of its intelligent warehousing solutions, providing customized solutions for more industries to reduce costs and increase efficiency, and promoting the accelerated implementation of intelligent manufacturing.