AiCart Clears the WIP Away

Applied Integration worked with a customer to automate the movement, storage, and retrieval of work-in-progress (WIP) across the production floor. The result was a fully integrated solution that removed floor congestion, improved operator access, strengthened stock control, and created a safer, more efficient manufacturing environment.

The Challenge

The original process relied on operators manually removing product from machines and placing it onto pallets beside the line. These pallets often remained in place for days or weeks until full, causing WIP to build up around machines and spill into walkways, creating access and safety issues.

The customer initially considered using conveyors between machines to move product to line ends for AMR collection and transfer into an ASRS. However, during design it became clear that conveyors would create even greater access problems by blocking direct operator movement between machines.

The Solution

Applied Integration developed a more flexible alternative using the AiCart system.

Dedicated drop-off and pick-up points were created around each machine. When needed, an AMR delivered an empty AiCart to the drop-off point. Operators could then wheel the AiCart to the machine, load product directly onto it, and place it in a collection zone.

AMRs scanned for waiting AiCarts, collected them automatically, and transferred them to the ASRS, where products were scanned, weighed, and stored in a known location. When required for the next stage of production, operators could request product retrieval through the visualisation system using FIFO or weight-based selection.

The Integrated System

The completed solution provided a fully automated internal logistics flow including:

WIP collection from machine areas
AMR delivery and collection of AiCarts
Automated transfer into ASRS
Product scanning and weight verification
Known-location storage
FIFO or weight-based retrieval
Delivery back into the next production stage

The system operates using 7 AMRs and 22 AiCarts.

The Outcome

By removing static floor storage and avoiding fixed conveyors between machines, Applied Integration significantly improved the flow of WIP through the factory.

The solution cleared the production floor, improved safety and access, increased visibility of product location, and strengthened stock control. The result is a cleaner, leaner, and more controlled manufacturing operation, with product moving efficiently from machine to storage and back into production when needed.