Implementing AMR robots in an operational manufacturing plant streamlines internal transport without requiring major changes to existing infrastructure. However, for automation to deliver the expected results without disrupting ongoing production, the entire process must be carefully planned—from analyzing material flows and selecting equipment to integrating the robots with production and warehouse management systems. How, then, can autonomous mobile robots be effectively implemented, their safe operation ensured, and a solution created that can evolve alongside the enterprise’s growing needs?
Preparing the facility for AMR implementation – analysis of processes and infrastructure
The first step is a detailed analysis of material flow. This allows for the identification of repetitive transport operations that can be automated without interfering with key production processes. Of particular importance are component deliveries to workstations, the collection of finished goods, and pallet transport between the production line and the warehouse.
The logistics audit should take into account transport cycle times, load weights and dimensions, delivery frequency, and required throughput. Based on this data, it is possible to estimate the number of robots needed, plan routes, and determine the potential benefits of the investment.
Assessment of infrastructure and technical conditions
AMRs utilize autonomous navigation, so they do not require the installation of induction loops or fixed travel paths. However, it is necessary to assess the condition of the flooring, aisle widths, surface gradients, and the locations of intersections and high-traffic zones. For instance, the MiR250 robot in its standard configuration requires an operating aisle width of approximately 1,450 mm, whereas the MiR1350 requires about 1,800 mm. Final requirements depend on the device configuration, the load being transported, and the safety measures implemented.
It is also necessary to verify Wi-Fi coverage, designate automatic charging points, and prepare load pickup and drop-off locations. Properly designing the infrastructure at the outset of the investment facilitates the future expansion of the AMR fleet.
Selection of AMR robots
The choice of the right AMR should be dictated by the specific nature of the logistics processes carried out at the facility. Key factors include not only the weight and dimensions of the loads being transported but also the required throughput, available maneuvering space, transport frequency, and the method of material transfer between individual workstations. A properly selected AMR should become an integral part of the existing production process, ensuring smooth material flow without the need to reorganize the entire infrastructure.
Lintegra’s product range includes autonomous mobile robots from MiR (Mobile Industrial Robots), designed for both the transport of small components and the handling of heavy pallet loads. The various models differ in their technical specifications, making it possible to match the device to specific operating conditions.
MiR AMR robots – technical specifications and applications
For transporting smaller loads—such as containers of components, production parts, or materials delivered directly to workstations—the MiR250, with a maximum payload of 250 kg, may be a suitable solution. The robot reaches speeds of up to 2 m/s and offers an active operating time of up to 13 hours at maximum load. Its compact design allows for efficient movement in confined spaces, which is particularly important in facilities with a high density of production stations.
The MiR600, with a payload capacity of up to 600 kg, is designed for transporting heavier components, semi-finished goods, and palletized loads. The unit reaches speeds of up to 2 m/s and offers up to 8.5 hours of active operation at maximum load. By utilizing appropriate top modules, it can interface with automated loading stations and conveyor systems.
For processes requiring the movement of significantly heavier transport units, the MiR1350—featuring a maximum payload of 1350 kg—is the ideal choice. This robot reaches speeds of up to 1.2 m/s and requires a standard operating aisle width of approximately 1800 mm. It is designed to handle heavy loads in production and warehouse environments where automating high-intensity transport is essential.
The MiR1200 Pallet Jack—an autonomous pallet-handling robot with a payload capacity of up to 1200 kg—represents a distinct category. It is equipped with integrated forks and a vision system utilizing machine learning algorithms, enabling it to recognize and automatically pick up pallets. The unit reaches speeds of up to 1.5 m/s, with a maximum fork lifting height of 1140 mm. This allows it to perform pallet transport tasks between production, buffer, and warehouse zones.
Integration of AMR robots with end-of-line automation
However, selecting the right device is only one element of the implementation process. To fully harness the potential of autonomous transport, it is essential to ensure seamless cooperation between the robots and existing technological infrastructure. Integrating AMRs with end-of-line automation—including palletizing, packaging, stretch-wrapping, and conveyor systems—is particularly important in this context.
For instance, a robot equipped with the appropriate top module can automatically pick up a pallet after the stretch-wrapping process and deliver it to the finished goods warehouse. The use of roller conveyors, lifts, or dedicated transfer stations enables load transfers without requiring operator involvement in every transport operation.
Integrating AMRs with the enterprise’s IT systems is another crucial aspect of implementation. Linking fleet management software with WMS, MES, or ERP systems allows for the automatic generation of transport orders based on current production needs and inventory levels. In the case of MiR robots, this function is supported by the MiR Fleet system, which enables centralized management of multiple units, task allocation, route optimization, and traffic coordination in shared spaces. The software also manages the battery charging process, thereby minimizing the risk of unplanned transport interruptions.
Thanks to proper integration, robots can respond to the real-time needs of individual workstations, and material transport becomes part of a synchronized production process. Automation then encompasses not only the physical movement of loads but also the intelligent management of the entire material flow within the facility.
Deployment of AMR robots in a production environment
In an operational production facility, the phased launch of the system is of particular importance. Rather than automating all transport operations simultaneously, it is advisable to start with a single route featuring predictable traffic volume and clearly defined pickup and delivery points.
A pilot implementation allows for the assessment of robot performance under real-world conditions. Testing should cover standard runs, automatic load pickup, communication with higher-level systems, and responses to emergency situations – such as route obstructions or a loss of connectivity.
AMR Safety in Mixed Traffic
One of the key challenges is organizing the space shared by robots, workers, and traditional forklifts. A safe implementation relies on a detailed risk assessment that takes into account factors such as travel speeds, stopping distances, and proper traffic organization at intersections and in shared zones. MiR robots utilize laser safety scanners and sensors to assist in obstacle detection. However, this does not eliminate the need for appropriate zone marking, the configuration of safety functions, and staff training.
Scaling the AMR fleet
The next stage involves the gradual expansion of automation to other areas of the facility. The decision to increase the number of robots should be based on an analysis of actual operational metrics, such as order fulfillment times, the number of transport runs per shift, equipment availability, and the frequency of unplanned stoppages. Monitoring battery usage and route throughput is also crucial. Centralized AMR fleet management enables the coordination of multiple units, the mitigation of congestion, and the adjustment of transport priorities to meet current production needs.
At Lintegra, we combine modern AMR technologies with expertise in production and intralogistics automation, delivering solutions tailored to the specific needs of each facility. Looking to streamline internal transport and boost process efficiency? Discover our range of solutions and see how autonomous mobile robots can transform logistics within your company.