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T&W Operations Replaced Forklifts and Manual Checks with Autonomous RFID Robots

Case-study

12/15/2022

Warehouse automation with OMRON’s LD-250 AMR

Industry

Logistics

Application

Transport

Robot Solution

LD-90, LD-250, HD-1500

From manual forklifts to fully autonomous inventory

T&W Operations, a Huntsville-based provider of smart RFID inventory solutions, faced persistent inefficiencies and errors caused by manual inventory checks and forklift-dependent workflows in their shipping, receiving, and warehouse systems. The goal: eliminate every manual process and transition to a fully hands-off, automated RFID operation using OMRON’s Autonomous Mobile Robots (AMRs).

The solution uses OMRON’s LD-250 and HD-1500 AMRs to power T&W’s Expandable Robotic Tower Inventory System (TIS-ER). This autonomous tower navigates warehouse aisles, scanning and verifying RFID-tagged inventory at heights up to 30 feet—no human intervention required. The LD-250 handles payloads up to 120kg and operates in areas with racks under 10 feet, while the HD-1500 supports up to 1500kg for facilities with tall storage.

Throughout the manufacturing workflow, OMRON AMRs handle containers from start to finish. They autonomously retrieve containers, check their contents digitally, and move them through RFID portals for precise, hands-off verification. This automation extends to the warehouse, where AMRs use real-time mapping and safety-rated sensors to navigate without facility modifications. The robots adapt to obstacles, coordinate as a fleet, and can be redeployed as layouts change. The TIS-ER tower adjusts its height on the fly for flexible inventory checks.

Since implementing these solutions, T&W Operations has achieved a 100% person-less RFID warehouse system, with over 30% greater inventory accuracy, improved cleanliness, and reduced labor needs. While every facility is unique, our automation experience shows that fully autonomous inventory management is scalable and flexible—even for organizations facing labor shortages and rising accuracy demands.

Watch T&W Operations‘ story:

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Results at a glance:

100% hands-off RFID inventory verification—no manual checks or forklifts
Autonomous mobile robots with flexible payload and height options
Real-time obstacle avoidance and adaptive mapping
Scalable solutions for both logistics and manufacturing environments
Improved inventory accuracy and operational cleanliness

Tailored automation for your operations

OMRON’s hands-off inventory management has helped T&W Operations free up their team for higher-value work and virtually eliminate manual errors. If you’re exploring ways to streamline your own operations, we’d be glad to share what we’ve learned—just reach out to start the conversation.