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Manual Parts Handling Reduced by 60% with AMR Logistics Automation
Automotive
Transport
LD-90
Paving the way for flexible and efficient material flow
BMW, a leading German automotive group, sought to streamline material flow across its dynamic assembly lines, where over 60% of production staff time was spent manually transporting components. Traditional conveyor systems were not practical due to frequent layout changes, and the existing AGV solution was limited by fixed routes that couldn’t adapt to evolving production needs. To address these challenges, BMW partnered with OMRON and cts GmbH to implement a flexible logistics automation solution based on Autonomous Mobile Robots (AMRs) equipped with height-adjustable conveyor attachments.
This integrated system, powered by OMRON’s LD-90 AMRs, now ensures reliable, just-in-time delivery of materials directly to the line, reducing manual handling by 60%. Employees are able to focus on more skilled tasks, while production cycles move faster and more efficiently. Real-time integration with BMW’s ERP system allows dynamic task assignment and route optimization, enabling the AMRs to adapt instantly to any changes on the factory floor.
The result is a scalable, fully traceable logistics process that improves productivity, supports flexible manufacturing, and provides measurable efficiency gains—demonstrating how advanced automation can transform intralogistics in a modern automotive environment.
Watch BMW’s story:
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“Developing an overall system based on the Omron LD, that meets the high requirements of a premium manufacturer like BMW, was a challenge that we gratefully accepted… Together with Omron and BMW, we were able to implement the ideal solution very quickly and successfully.” — Alfred Pammer, Head of Factory Automation, cts GmbH
Results at a glance:
- 60% reduction in manual material handling for production teams
- Flexible, autonomous routing—no fixed infrastructure required
- Millimeter-accurate material delivery in crowded factory spaces
- Seamless integration with enterprise resource planning (ERP) systems
- Scalable solution now deployed at multiple BMW production sites
Flexible material flow for automotive manufacturing
In automotive manufacturing, production requirements can shift quickly, and material delivery needs to keep pace. With OMRON LD-90 AMRs and conveyor attachments, BMW improved internal transport while giving production teams more time to focus on higher-value work. The solution supported consistent, efficient material flow without requiring infrastructure changes.
If similar challenges are part of your day-to-day operations, our team can help explore practical automation options that fit your facility.
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