Case Studies

AMR-Based Material Handling in a Snack Manufacturing Facility

Eliminating factory congestion with smarter traffic control, zero misrouting, and efficient multi-product handling at scale.

March, 2021
AMR-Based Material Handling in a Snack Manufacturing Facility

Introduction

A leading snack manufacturing company in India faced operational inefficiencies due to high product variety, limited floor space, and increasing internal traffic. The facility handled multiple types of packaged snack products, each requiring accurate and timely transfer across production stages.To address these challenges, a multi-AMR automation system was deployed in collaboration with OEM partners, focusing on traffic control, workflow optimization, and error-free material handling.

Problem Statement:

Existing Workflow:

  • Human-operated forklifts used for transferring finished goods. There are multiple product types with different packaging formats. Limited operational space with increasing traffic.

Key Issues:

  • Product Damage Risk

    Snack packages are fragile, frequent handling increased chances of:

      • Crushing
      • Misalignment
      • Damage during transport
  • Product Misplacement & Human Error

    Multiple SKUs created confusion for forklift operators Increased risk of:

      • Wrong deliveries
      • Misrouting of finished goods
Takeaways

Key Takeaways from This Case Study:

Eliminated traffic bottlenecks caused by forklifts. Smoother and faster material flow across production. Controlled and stable handling minimized damage to fragile packages. Automated routing eliminated product misplacement, human errors in handling multiple SKUs.

By replacing forklift-based operations with an intelligent, software-driven system, the company achieved higher efficiency, improved accuracy, reduced product damage, and seamless multi-AMR coordination—creating a scalable foundation for future production growth.

TakeawaysTakeaways
Our RoleOur RoleOur Role

Vrutti’s Role:

Implementation Strategy:

  • Key Capabilities:
    • Autonomous material transfer across production stages.
    • Centralized fleet control for multi-AMR coordination.
    • Software-driven task allocation based on workflow demand.
    • Seamless integration with OEM AMR platforms.
  • Workflow A Synchronization:
    • Alignment with multi-product production lines.
    • Intelligent task allocation system to manage:
      • Different product flows
      • Priority-based transfers
    • Queue management for continuous and error-free operations.
  • Testing & Optimization
    • Validation across multiple product types and packaging formats.
    • Iterative tuning for:
      • Navigation efficiency in tight spaces
      • Accurate delivery and routing

Traffic Control Built for Multi-AMR Systems:

With multiple AMRs operating in a space-constrained environment, advanced traffic control was critical.

System Highlights:

    • Collision-free navigation even in high-density traffic zones.
    • Intelligent routing to avoid congestion and deadlocks.
    • Seamless coordination between multiple AMRs without manual intervention.

"Optimizing high-density factory operations with AMR-driven automation—eliminating congestion, reducing product damage, and enabling accurate multi-product handling at scale."

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