Test by Mahle Behr proves autonomous robots can take auto parts inventory

Dec. 12, 2017
Auto parts manufacturer Mahle Behr tested a new robotic cycle counting solution, working with digital supply chain solution provider Surgere and Fetch Robotics to test the system at its Dayton, Ohio, facility.

Auto parts manufacturer Mahle Behr has wrapped up a pilot test of a new robotic cycle counting solution. Mahle worked with digital supply chain solution provider Surgere and Fetch Robotics to test the system at its Dayton, Ohio, facility.

Mahle is using Surgere’s Robotically Optimized and Balanced Inventory (ROBi) platform, combined with RFID tags, the company’s cloud-based asset management supply chain analytics system (COS) and Fetch’s robot technology.

According to David Zingery, head of strategy and growth at Surgere, the ROBi system grew out of Surgere’s experience in developing asset tracking and inventory tracking solutions. “Over the years we’ve deployed a number of different RFID portals and handheld systems, and we wanted to come up with a way to propel that into an autonomous, hands-off entry point,” Zingery says. “We liked Fetch’s platform. It had all the things we needed: WiFi, power, robust mapping, sensors, LIDAR, etc. You can map the area and tell the robot where it can go and where it’s not allowed to go.”

Surgere and Fetch tested preliminary models before installing the robots at the Dayton plant. Now the companies are offering the solution to other customers.

Real-time visibility

ROBi can help companies maintain real-time visibility of parts and assets without throwing labor at the problem.

“You’ve got a cost per person for the folks who are walking around just to count boxes,” Zingery says. “As things move in and out of the warehouse, there’s no way to tell how accurate those cycle counts are.”

William Wappler, president and CEO of Surgere, agrees.

"Even with workflow management systems (WMSs) in place, many of our clients find the fast-paced automotive part and container inventory storage, retrieval, and distribution process to often be ad hoc, time-intensive, error-prone and costly. Without supporting technology, it can be a process in chaos," says Wappler. "After rigorous testing and evaluation, we've arrived at a place where our decision was solidly in favor of robotics over drones and other mobile and fixed devices. We found ROBi is a much more accurate and granular form of RFID data acquisition in automotive environments. Using ROBi technology; inventory tracking takes place constantly, consistently, quietly, safely and accurately."

By scanning an RFID tag on the container, companies can associate extended information about items inside the container. The robots can then scan the tags to more accurately collect location data than is possible with manual approaches.

“Inside a facility we have deployed systems where employees use handheld units like a Geiger counter to locate RFID-tagged assets,” Zingery says. “With the robot, you have a hands-off method of doing that. You can set a schedule and map the location, and set different paths and orientations to run at certain times of the day.”

The robot (based on the Fetch TagSurveyor platform) can locate and count RFID-tagged items automatically and autonomously in order to cut labor from the cycle process and create a reliable map of part locations within a facility.

San Jose-based Fetch provides robotic solutions that are equipped with obstacle avoidance features that can help them avoid potential collisions with employees and equipment. They also slow down when approaching blind corners. The ROBi hardware also includes three RFID readers set at different angles and heights.

Moving on programmable routes, the solution transfers asset identification and location data to Surgere's cloud-based asset management system, which validates and provides documentation of where tagged packaging, parts, tools and other assets are located inside a distribution center. ROBi's data acquisition also accounts for height of stacked or racked product above floor, depth within shelving, and the speed of robotic travel, so it can scan for assets anywhere in the building.

In the Mahle facility, the robots scanned containers on three-tiered racks. According to Zingery, the RFID readers were able to scan tags up to 82 degrees from the unit. Mahle’s 570,000-square-foot Dayton factory makes heater cores, HVAC modules, radiators, fan clutches and engine cooling modules.

“We conducted velocity testing as well, and we kept working through different settings and adjustments to make sure we knew where to position the robot in the aisle,” Zingery says. “We wanted to get the read height and depth right, and the optimal speed.”

The companies also wanted to ensure the robots could operate safely alongside employees. The robots include safety lights so that employees can see it coming, and it’s layered with sensors and built-in logic to avoid obstacles.

Zingery says the solution would work best for a facility with high inventory turnover or large quantities of items that move in and out of the facility. “You would combine this with other technology in a layered approach,” he says. “You scan goods as they come into the facility, and you also record the items autonomously as the robot is moving around at different times. You can even combine this with GPS or other environmental sensors as well.”

With the pilot completed, Surgere is already in discussions with other companies in the industry about using the solution.

“We are looking at doing other things with Mahle in the coming year, and we have other automotive opportunities as well,” Zingery says.

Subscribe to Aftermarket Business World and receive articles like this every month….absolutely free. Click here.

Sponsored Recommendations

ZEUS+: The Cutting-Edge Diagnostic Solution for Smart, Fast, and Efficient Auto Repairs

The new ZEUS+ simplifies your diagnostic process and guides you through the right repair, avoiding unnecessary steps along the way. It gives you the software coverage, processing...

Diagnostic Pre- and Post-scan Reports are Solid Gold for Profitability

The following article highlights the significance of pre-scans and post-scans, particularly with Snap-on scan tools, showcasing their efficiency in diagnosing issues and preventing...

Unlock Precision and Certainty: TRITON-D10 Webinar Training for Advanced Vehicle Diagnostics

The TRITON-D10 lets you dig deep into the systems of a vehicle and evaluate performance with comparative data, systematically eliminating the unnecessary to provide you with only...

APOLLO-D9: Trustworthy Diagnostics for Precision Repairs

The APOLLO-D9 provides the diagnostic information and resources you need to get the job done. No more hunting through forums or endlessly searching to find the right answers. ...

Voice Your Opinion!

To join the conversation, and become an exclusive member of Vehicle Service Pros, create an account today!