It is possible to develop an AGV loop in 24 hours

AGV loop AGV for lean manufacturing

It is possible to develop an AGV loop in 24 hours

Have you ever wanted to incorporate AGV loops into your layout, but never really knew where to start? Does your notion of AGV loop does not seem iterative enough and too important to be carried out in a single day? Do you understand the link between takt times and logistics loops?

Look no further! We have put together our extensive knowledge on the subject. Find out how to use testing and learning techniques to create an effective AVG loop. Learn to create in a short time, while learning more and more.

Here are our 3 quick and easy tips for creating an effective AGV loop.

#1 Reduce the batch size and find your standard

The first step, and probably the most important, is to get rid of the idea that you will continue to deliver the same way you did yesterday. Never do the same again! Change your mind about batch sizes and get rid of 500 kg deliveries. What if you change and deliver smaller sizes, for example 12 kg? This way, it will be easier to carry it by hand and by robot. If you have large parts to transport you can go up to 20 kg, but beyond that weight the boxes become more and more difficult to handle.

Yesterday you were delivering massive shipments at once. These are heavy containers, large boxes, loaded pallets or even piles of overflowing coins. This method is absurd. How about a continuous flow for your factories? Reduce your batch size to create a seamless material flow.

Nowadays you have to take the next step and figure out how to reduce the size of your loads. A smaller batch will be easier to transport and simpler to deliver. Using standard containers is incredibly beneficial to the workflow and material flow in your plant. You can follow Toyota’s lead! Their production system (TPS) is constantly learning how to reduce batch sizes, allowing them to see problems faster. And the sooner you locate a problem, the faster you can practice continuous improvement.

#2 Plan small projects to learn better

Although some large projects span several years, the best way to gain the best experience with configuration changes is to use an iterative process. An iterative process means that small tests are done and a feedback loop is created to extract as much information as possible from the experience.

Information about problems and setbacks encountered along the way becomes learning material to improve the project in the future. By breaking down the process into smaller, more manageable portions, deliveries become smaller, faster and more regular. Installing an AGV loop becomes a cycle of learning opportunities.

Here is an example of implementing an AGV loop by iteration:

1st step: Deliver 1 specific part to 1 workstation
2nd step: Deliver 1 specific bin to 1 workstation
3rd step: Deliver 1 specific bin to 2 workstations
4th step: Deliver 2 specific bins to 2 workstations
5th step: Deliver 2 different bins to 2 workstations
6th step: Keep doing continuous improvement!

#3 Rendre les livraisons plus rapides et plus fréquentes

The next tip is to speed up the AGV circuit, making it loop more evenly. As it goes to its place of delivery more frequently, the size of the stocks is reduced. As an example, let’s see some suggested cycle times and deliveries by AGVs for workstations in a production plant.

Takt timeObjectif de livraison AGV
60 seconds30 minutes
20 minutes60 minutes
280 minutes60 minutes (yes, really!)

Have you ever heard of a milkrun? The origin of the milkrun dates back to the 1900s in rural America, where a train frequently stopped at farms to collect milk cans, which were then sent to dairies for bottling. This process has since been adopted by the manufacturing industry and it is used to describe a method that accelerates the flow of materials within and between factories. The material supplier, or delivery person, delivers the parts to different stations in sequence on a fixed schedule.

As the milkrun, this new version uses fixed routes to make multiple collections or deliveries. Instead of waiting for sufficient deliveries to each location to fill a truck or cart, this method reduces inventory size and response time on the production line. Instead of going back and forth between sites, you develop a loop.

Create a logistics loop by AGV in 24 hours:

You will be able to set up an AGV loop without any problem. Keep in mind that an AVG loop serves to smooth a flow, thus creating a continuous and flawless flow of material. This is one of the best ways to detect issues, and by understanding your issues, you can come to truly understand your flow.

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