85% Material Flow Automation in the Plant
Volkswagen Slovakia autonomously supplies body shop operations in Bratislava with material: the SYNAOS Intralogistics Platform orchestrates a mixed AGV fleet from Asseco CEIT based on VDA 5050. The material flow in the body shop is now 85% automated.
All Skoda Superb and all VW Passat models are produced in the body shop of Volkswagen Slovakia in Bratislava. The intralogistics operation there is highly complex and subject to intense cost pressure. The project was built as a greenfield project at a brownfield site: a new hall, a newly assembled team and new vehicles from hardware partner Asseco CEIT. The central requirement was to operate different vehicle types within a shared material flow, without isolated solutions per manufacturer or vehicle type.
Solution
The SYNAOS Intralogistics Platform controls the entire AGV fleet via a single platform and is integrated into the Volkswagen IT landscape.
43 vehicles in four types: two underride AGVs and two fork lift AGVs. Since filming, an additional area of hall H6 and hall H1 have been added. SYNAOS currently orchestrates 89 vehicles at the site.
Over 200 transfer stations covering different load carriers
VDA 5050 as the communication standard. Interpretive ambiguities in the standard, for example regarding pick-up and drop-off for fork lift vehicles, were jointly defined by SYNAOS and Asseco CEIT.
Manual and automated processes work in concert: DHL provides material based on real-time consumption data, while the mobile robots handle onward transport.
Older vehicles were upgraded to VDA 5050 and are also running on the SYNAOS software.
Results
85% degree of automation in the body shop material flow
Over 500 kilometres of autonomous driving performance per day
Real-time transparency across all orders, including requested time, receipt time and delay
Scaling: Since filming, an additional area of hall H6 and hall H1 have been added. SYNAOS currently orchestrates 89 vehicles at the site.
