AMR Autonomous Forklift Enables Seamless Multi-Floor Logistics in Luggage Manufacturing

 

Why Multi-Floor Logistics Becomes a Bottleneck

In the luggage manufacturing industry, efficiency and cost control are decisive factors. Traditional factories often rely heavily on manual forklift operations for cross-floor transport. Raw materials are moved from ground-floor warehouses to upper production floors through manual pallet handling, elevator waiting, and unloading. Each trip can take over 20 minutes, creating delays, errors, and high labor turnover.

A large luggage manufacturer with annual output exceeding 800,000 units faced exactly this challenge. During peak seasons, production lines frequently stalled due to delayed material delivery, while labor turnover in transport roles exceeded 40 percent annually.

Rapid Deployment of Autonomous Forklifts

In early 2024, the factory deployed three Reeman AMR autonomous forklifts. Within one week, mapping, elevator integration, and workflow configuration were completed without disrupting production.

The forklifts operate across a three-story facility where the ground floor stores raw materials, the second floor handles semi-finished processing, and the third floor manages final assembly and outbound logistics. Hundreds of cross-floor transport tasks are executed daily.

Autonomous Navigation and Precise Pallet Handling

Reeman AMR autonomous forklifts use advanced laser SLAM navigation to build high-precision 3D maps with positioning accuracy within ±10 mm. Even in environments with frequent personnel movement and temporary obstacles, the system dynamically plans optimal routes.

For pallet handling, the forklifts integrate vision recognition and infrared sensing. Different pallet sizes and load conditions are automatically identified, enabling stable and accurate pickup of loads ranging from 600 kg raw materials to 800 kg finished products, with smooth motion and no load instability.

Fully Automated Elevator Integration

A critical breakthrough is autonomous elevator operation. The forklifts communicate directly with the elevator control system via wireless connection. When cross-floor transport is required, the forklift autonomously calls the elevator, verifies cabin space using LiDAR, enters with millimeter-level accuracy, and exits on the target floor without human intervention.

This automation reduced single cross-floor transport time from over 20 minutes to under 8 minutes, improving efficiency by more than 60 percent and eliminating elevator congestion caused by manual forklifts.

Measurable Performance Improvements

The three forklifts operate collaboratively under an intelligent scheduling system. Tasks are distributed dynamically based on priority, avoiding conflicts and idle time.

Daily pallet transport increased from an average of 288 trips with eight workers to more than 320 automated trips, with peak days reaching 368. Product damage rates dropped from 1.8 percent to 0.3 percent, saving the factory over 120,000 RMB annually.


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