How Automotive Tier Suppliers Are Using Autonomous Mobile Robots to Improve Safety and Productivity

By Sheldon Zimmerman

Automotive tier suppliers are operating in a landscape of relentless pressure—tight deadlines, stringent quality standards and rising cost demands. As the automotive industry evolves, suppliers face a critical need to innovate their processes, particularly in material handling, to stay competitive. One standout technology transforming the landscape is autonomous mobile robots (AMRs), which are helping suppliers modernize material handling processes without requiring substantial infrastructure investments.

This article delves into how AMRs are helping tier suppliers revolutionize material handling, cut costs and create safer workplaces—all without the burden of extensive infrastructure upgrades.

The Move to AMRs

For decades, automotive tier suppliers have relied on traditional systems such as manual tuggers, forklifts and automated guided vehicles (AGVs) to handle materials. These systems, while functional, are not without their challenges. Fixed infrastructure requires significant upfront investment and is often rigid, making it difficult to adapt to changing production needs. AGVs, for example, often demand predefined paths and facility modifications, leaving little room for flexibility in dynamic manufacturing environments.

AMRs offer a compelling alternative. These robots leverage cutting-edge technology—including sensors, cameras and machine learning—to navigate autonomously through warehouses and manufacturing facilities. Unlike AGVs, AMRs can respond dynamically to their surroundings, enabling quick adjustments to shifting production demands without costly facility changes. Their adaptability and ability to coexist with existing workflows make AMRs an increasingly attractive option for tier suppliers aiming to modernize without causing major disruptions.

Driving Down Costs

One of the primary drivers for adopting AMRs is the potential for cost reduction. Labor costs, a perennial challenge for manufacturers, are particularly significant in regions facing a shortage of skilled workers. By automating repetitive material handling tasks, AMRs reduce reliance on manual labor, allowing employees to focus on more skilled, value-added activities. This shift not only increases operational efficiency but also minimizes human error, which can lead to costly production delays or quality issues.

Scalability is another cost advantage of AMRs. Unlike fixed systems that require substantial retrofitting for expansion, AMRs can be incrementally deployed to meet growing demands. This modular approach allows tier suppliers to scale operations as needed, responding swiftly to market fluctuations or unexpected disruptions. For example, during a new vehicle launch or supply chain bottleneck, AMRs can be easily reprogrammed to prioritize urgent tasks, making them a cost-effective solution for dynamic production environments.

Boosting Productivity

Beyond cost savings, AMRs unlock significant productivity gains for tier suppliers. Their ability to operate continuously—day and night—ensures timely delivery of materials to the right locations, eliminating bottlenecks and maintaining a steady flow of production. This seamless material movement enhances operational efficiency, enabling suppliers to meet OEM demands with greater precision.

AMRs are also versatile in their material handling capabilities, accommodating everything from small components to large assemblies. This flexibility allows suppliers to assign diverse tasks to AMRs, such as transporting raw materials, moving work-in-progress items or delivering finished products. With the ability to adapt to changing production layouts and schedules, AMRs prove invaluable in fast-paced manufacturing settings.

Additionally, AMRs provide actionable insights by collecting data on material flow. By analyzing this data, tier suppliers can identify inefficiencies in real-time and implement targeted improvements, leading to continuous process optimization and higher overall productivity.

Making Workplaces Safer

Safety is a critical concern in manufacturing environments, where heavy equipment, congested spaces and physical labor introduce significant risks. AMRs contribute to safer workplaces by taking on tasks that are traditionally hazardous or physically demanding for workers.

Equipped with advanced sensors and obstacle detection systems, AMRs are designed to safely and reliably navigate complex factory environments, ensuring they do not collide with objects or personnel. This technology helps ensure accidents involving forklifts or manual handling equipment are prevented. By automating risky tasks, AMRs help create a safer environment.

The Road Ahead for Tier Suppliers

The role of AMRs in material handling is poised to expand as the automotive industry grows and evolves. For tier suppliers, AMRs offer a strategic advantage in navigating these demands. Their ability to integrate seamlessly with existing systems, adapt to new challenges and provide actionable insights positions them as a critical asset for future-proofing operations.

Sheldon Zimmerman is Director of Automotive Sales, OTTO by Rockwell, a company whose mission is to create safer, more productive and more fulfilling workplaces for manufacturers around the world with the most comprehensive autonomous material handling solution. https://ottomotors.com/