Innovate non-standard truck head warehousing and create a new benchmark for smart logistics!

What challenges does truck head storage present?

Introduction

In the automotive manufacturing industry, traditional warehousing models often face the following challenges due to the varying sizes, heavy weight, and low storage space utilization of non-standard truck heads:

• High labor dependency: Manual handling and record-keeping are inefficient and prone to errors;
• Information silos: Data coordination between the production side (MES) and the warehouse side (WMS/WCS) is poor;
• Space waste: Non-standard goods are difficult to store densely, resulting in insufficient storage capacity.

To address this challenge, Shengyide Intelligent developed a customized intelligent vertical storage solution for non-standard truck heads for a leading automotive company in Beijing. Through the deep integration of software and hardware, this solution achieves full process automation, data visualization, and intelligent scheduling.

Core Solution: Software and Hardware Collaboration, Technological Breakthrough

1. Hardware Architecture: High-Precision Equipment and Intelligent Scheduling System

Customized 3D Shelving: Dynamically adjusts shelves based on vehicle head size, improving space utilization by 40%.

Stacker Crane + RFID Technology: The stacker crane is equipped with a high-precision positioning module that automatically reads vehicle frame information using an RFID chip, achieving an identification accuracy rate of 99.9%.

PBS Conveyor Line Interconnection: After painting, the vehicle head is automatically transported to the 3D warehouse entrance via the PBS line, seamlessly connecting production and warehousing.

Pain Points: The Achilles' Heel of Traditional Warehousing

Difficulty Adapting to Non-Standard Car Heads: Car head lengths range from 3.5m to 5.2m, and traditional racking has a low error tolerance.

Low Labor Efficiency: Inbound and outbound operations rely on manual recording, resulting in a 5% error rate and processing of only 30 pallets per hour.

Data Silos: The MES and warehouse systems are disconnected, resulting in inventory information delays exceeding one hour.

2. Software System: Multi-Platform Collaboration, Fully Integrated Data

Inbound Process: Car head RFID information is interactively generated by the WCS, and tasks are synchronized to the WMS in real time after execution by the stacker crane. Inventory data is pushed to the MES every minute.

Outbound Process: The MES sends queues to the WCS, and the stacker crane executes tasks based on priority. Task completion signals are transmitted back in real time, and inventory is dynamically updated.

Intelligent Scheduling Algorithm: Optimizes inbound and outbound routes based on historical data, reducing the stacker crane's idle load rate and improving efficiency by 40%.

Hard Data: Visible Cost Reduction and Efficiency Improvement.

3. Technical Highlights: From Automation to Intelligence

▸3D Vision Scanning Ultra-precision modeling and dynamic positioning
▸RFID chip binding: One vehicle, one code, full lifecycle traceability
▸AI palletizing algorithm: Mixed stacking of irregular-shaped vehicles, increasing space utilization by 40%
▸Superfast response: WCS intelligent order scheduling, seamless stacking of stacker cranes
▸Direct connection between MES/WMS/ERP: Real-time synchronization of inventory information, reducing the misdelivery rate to 0.1%

Project Results: A Double Leap in Efficiency and Management
1. Efficiency Improvement: Inbound and outbound response times reduced from hours to minutes, achieving high daily throughput for vertical warehouses
2. Cost Optimization: Manual intervention reduced by 70%, increasing warehouse space utilization to 85%
3. Data Closure: Strengthening full-process traceability from production to warehousing, achieving 100% data consistency between WMS and MES
Ecosystem Empowerment: Building a digital closed loop for the entire automotive manufacturing chain (production, warehousing, and delivery)
Cost Revolution: Annual savings of 1.8 million RMB in O&M costs per warehouse, with a payback period of less than 2 years