INNOVATIVE SOLUTIONS FOR A DIGITAL FUTURE IN AUTOMOTIVE MANUFACTURING
Setting the stage
AUMOVIO’s plant in Brandys, Czech Republic, is not only one of the company’s long-standing production sites but also a hub for innovation in industrial automation. Recently, the facility has taken on a pioneering role as a testing ground for the DIAZI project, funded by the German Federal Ministry for Economic Affairs and Energy. The project’s mission is ambitious yet clear: to bring production plants into the digital world by enabling new production lines to be planned, simulated, and operated virtually before being realized on the shop floor. This digital-first approach drives higher efficiency, flexibility, and cost-effectiveness—while helping manufacturers keep pace with faster development cycles, complex supply chains, and evolving customer demands.
The Czech Republic has been rapidly advancing in warehouse automation and the adoption of cutting-edge technologies, positioning itself at the forefront of industrial transformation. As highlighted in a report by the World Economic Forum, “Technology adoption will remain a key driver of business transformation in the next five years.” For Aumovio, this adoption translates into the ability to expand and safely integrate its fleets with increasingly advanced and cost-effective AGVs/AMRs in response to a fast-evolving market.
At the center of this transformation is NAiSE, a trusted partner of AUMOVIO. Our collaboration extends across multiple plants, including the Brandys facility, where our joint efforts have introduced advanced solutions that significantly enhance operational efficiency, material flow, and overall productivity.
Addressing complexity in warehouse automation
Managing a diverse fleet of robots from multiple manufacturers within a single facility is a significant challenge—especially when some operate using the VDA 5050 standard, others use native (non-VDA 5050) interfaces, and manually driven vehicles also share the same space. This was the exact scenario at AUMOVIO’s Brandys plant.
To tackle this complexity, we deployed NAiSE’s Intralogistics Platform, creating a seamless connection between warehouses and production halls. Our solution ensures that all vehicles—autonomous or manual—can operate in harmony, improving coordination, reducing conflicts, and enhancing overall efficiency.
Use case participants
At AUMOVIO’s Brandys plant, a diverse range of autonomous solutions supports the facility’s complex material flow. This includes two types of AMRs with native (non-VDA 5050) interfaces. In total, three robots are actively operating in the facility: one dedicated to pallet transport and two handling boxes. These robots play a crucial role in maintaining efficient and reliable material handling processes.
In addition, manually driven vehicles—specifically tugger trains—remain an integral part of operations. They work seamlessly alongside autonomous robots, ensuring transparent, flexible, and smooth material flow throughout the plant.
Coordinating this mix of autonomous and manual vehicles requires a sophisticated system capable of integrating multiple technologies and workflows. NAiSE’s solution bridges this gap, enabling all participants in the material flow to operate in harmony and contributing to measurable improvements in overall plant productivity.
Process integration
NAiSE Intralogistics Platform ensures efficient connection and coordination of the various processes occurring in the warehouses and production halls.
Production Hall: AMRs are equipped with docking stations integrated into the storage system. These robots efficiently transport boxes within the production hall, docking to load or unload materials and navigating directly to designated locations.
Warehouse: A dedicated AMR handles pallet transportation between production halls, maintaining continuous material flow across the facility. After delivering full pallets, it retrieves empty pallets and returns them to the warehouse, optimizing storage utilization and ensuring materials are always available where needed.
Tugger Trains: Manually driven tugger trains complement the automated fleet by transporting pallets or boxes between storage and production areas. This hybrid approach guarantees a reliable supply of materials to critical points while maximizing the efficiency of storage spaces.
Automation of tugger trains
Our solution leverages the NAiSE Real-Time Localization System (RTLS) to precisely track manually driven vehicles across the facility. NAiSE RTLS continuously collects real-time location and movement data, feeding it directly into our software. This integration enables seamless coordination between autonomous and manual vehicles, minimizing downtime and optimizing overall operational efficiency.
At AUMOVIO’s Brandys plant, RTLS provides critical precision for tracking tugger trains. Hall and production managers can monitor the exact location of each vehicle at any moment. To achieve this level of accuracy, we strategically installed 54 anchors and 8 gateways throughout the facility.
In addition, we integrated automated door control systems. As material flow participants approach these doors, they enter custom-defined zones within the NAiSE software, triggering the doors to open automatically. This ensures uninterrupted material flow and enhances operational efficiency.
We also implemented projector-based signaling within defined zones. When a robot enters a designated area, projectors display visual cues (e.g., “STOP”) on the floor, instructing other participants to wait until the path becomes free. This system significantly improves safety, allowing humans and robots to operate in the same space without risk of accidents or disruptions.
Future goals
Our vision is to create a fully integrated environment where all participants—autonomous robots and manually driven vehicles—operate seamlessly across every area of the facility, including warehouses, production halls, and storage systems. This integration aims to further boost efficiency, productivity, and operational transparency throughout the plant.
By continuously advancing our technology and refining integration strategies, we strive to establish a fully optimized, automated environment that sets new standards for warehouse operations and material handling. The Brandys plant serves as a key testing ground for these innovations, including the latest achievements from the DIAZI project, funded by the German Federal Ministry for Economic Affairs and Energy.
