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Manual Parts Handling Reduced by 60% with AMR Logistics Automation

Case-study

8/16/2021

LD-90 AMR transporting components in an automotive manufacturing facility_cropped

Industry

Automotive

Application

Transport

Robot Solution

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

Rethinking material flow in automotive manufacturing

With the introduction of OMRON LD-90 AMRs and conveyor attachments, BMW production teams have been able to focus on higher-value work while maintaining consistent, efficient material delivery—even as production requirements evolve. This flexible approach to logistics automation has streamlined workflows and supported continuous improvement, all without the need for infrastructure changes.

Curious how this kind of solution could work in your facility? We’re always happy to share insights and discuss what’s possible for your unique environment.