Magna opts for automated small parts warehouse and autonomous mobile robots for flexible production supply
Magna, one of the world’s largest automotive industry suppliers, is a mobility technology company with a global team. With 65 years of experience and a systems approach in the design, development and manufacturing of every aspect of the automobile, Magna is well equipped to redesign mobility during a period of major change. Magna has 341 manufacturing facilities and 89 product development, engineering and distribution centers in 28 countries.
Magna Spiegelsysteme GmbH in Assamstadt, Germany, specializes in vision systems. Their core area of expertise is the production of side mirrors for several premium original equipment manufacturers. Assamstadt is also home to the plastic injection molding, paint application and the final installation of the mirror systems.
To raise the vertical range of manufacture at the location, Magna invested in an automated small parts warehouse with an AMR transport solution.
20,300 storage locations
Process optimization at the highest level
Increasing global competition and an analysis of the internal processes indicated that Magna’s logistics and supply chain was due for an update. A solution was sought that would provide Magna with greater flexibility and increase the real net output ratio at the location. Combining the OSR Shuttle system with Open Shuttles delivers the flexibility boost Magna was looking for.
Requirements for the solution
Upon analysis of the parts, the variety and the quantities, it became rapidly clear that without an automated solution, we would not be up to the new challenges. With the Open Shuttles, our production lines are supplied and the OSR Shuttle warehouse can be operated automatically without personnel. This reduces internal traffic and ensures rapid availability of the parts.
OSR Shuttle Evo +: The plus in flexibility
The combination of an automated small parts warehouse, the OSR Shuttle Evo and the Open Shuttle autonomous mobile robots (AMRs) offers flexibility in all processes.
The OSR Shuttle Evo forms the heart of the solution. It supplies the multifunctional work stations with parts for the assembly of the side mirrors while also transferring containers to the Open Shuttles, which then transport them to the peripheral production lines, with materials arriving just-in-time and just-in-sequence. If there are changes to processes, transport routes or the sequence, or if urgent orders must be squeezed in, the system can respond very quickly. Control of the system is effected through KiSoft software connected to Magna’s ERP system.
Magna’s small parts warehouse with AMRs: A glimpse inside the solution
The solution has been in operation since 2022. Magna produces side mirrors for premium OEMs (original equipment manufacturers). In production, getting the sequence and the timing right is crucial. The individual mirrors must be supplied to the manufacturer’s assembly lines at just the right time.
The painted outer mirror parts for an order are delivered to the multifunctional work stations, where employees check them, identify them through barcodes and place them on trays for storage in the OSR Shuttle Evo. This work is easy on the employees thanks to the easyUse user interface and the ergonomic, intuitively operated work station.
Transport orders between the production lines for the side mirrors in the adjacent hall and the OSR Shuttle Evo are handled by six Open Shuttles. They connect the small parts warehouse with the peripheral production work stations, transporting both empty containers and finished pieces. Moving autonomously and safely avoiding people, they navigate their surroundings and transfer the containers to the conveyors.
Side mirrors, painted parts and empty containers are centrally stored in the OSR Shuttle Evo, from where they are retrieved when needed in production or assembly. The OSR Shuttle Evo comprises two rack line systems and 31 levels. Thanks to the dynamic triple-deep storage design, it has a storage capacity of 20,300 locations for containers measuring 600*400 mm (24*16 in). The system has two shuttles per level which handle all the storage and retrieval movements.
Directly connected to the small parts warehouse are the multifunction Pick-it-Easy work stations where the side mirrors are assembled. The side mirrors and the colored painted parts that go with them arrive at the work stations just-in-time and just-in-sequence. The user-friendly system guides the employees in the assembly of the side mirrors. The finished mirrors are then packed in the correct sequence on a pallet so that they arrive at the OEM at the right time and in the right sequence.
Thanks to this solution, we were able to increase the degree of value creation, improve flexibility and therefore offer our customers more value.
How Magna benefits from their small parts warehouse with AMRs
Simplicity and flexibility
The new solutions mean that processes are simpler and more efficient. Magna can now respond much faster to customer requests. The easy-to-operate work stations can be used flexibly, either for the goods-in process or for assembly, depending on the workload. The flexible Open Shuttles reduce in-house traffic and integrate seamlessly into the environment.
Expandability
The OSR Shuttle Evo is designed to allow future growth. The storage system can be expanded in terms of both storage locations and work stations. Connections to further production lines are easily possible with the Open Shuttles as well. When more performance and throughput are called for, more shuttles can be added to the storage system, including more Open Shuttles.
Profitability
This new system helps Magna supply their customers just-in-time and just-in-sequence, so they are no longer dependent on external service providers. By cutting their stock in half and thanks to the flexible and efficient handling of orders, the depth of value creation at the facility increased significantly.
