BORG Automotive is one of Europe's leading independent automotive remanufacturers, with more than 50 years of experience. The company approached us to bring order to the flow of components between the warehouse and production — not just faster transport, but full visibility and traceability of every KLT container. We designed a complete intralogistics system: SUPERVISOR assigns missions to three MiR250 robots, each fitted with our FORMIGA module – a dual-level roller system holding six KLT containers – and we send delivery confirmations, and we send delivery confirmations directly to the customer's MES system, so every inventory movement is recorded automatically.

Thousands of components move between the warehouse and production at the plant every day. Before automation, this ran as a manual milk-run process, and as volumes grew it became harder to maintain visibility and consistency. The company approached us with a need that went beyond faster transport: confirmation that every container reached the right destination, and automatic recording of inventory movements.

The process starts in the MES system. A production operator places an order, and the warehouse prepares the required KLT containers based on the picking list. LED indicators guide container placement on the loading rack, sensors verify loading, and once the predefined conditions are met the transport mission is generated automatically. The robot delivers components to multiple production sectors in an optimized sequence, collects empty containers, and returns them to the warehouse.

The key element of the solution is the SUPERVISOR software, which determines where each container should be loaded, assigns tasks to the robots through MiR Fleet, optimizes delivery sequences across sectors, and confirms completed deliveries back to the MES. Warehouse operations, production planning, and robot transport thus run as one coordinated process. For the MiR250 robots we developed the FORMIGA module – a dual-level roller system holding six KLT containers; we selected the platform for its compact footprint, which allows it to operate efficiently in narrow factory aisles. The system is completed by warehouse and production racks and our TRIGGERBOX IoT devices, which connect the rack sensors and LED signalling to the control system.

The biggest challenge was optimizing the entire process from the software and hardware side at once: MES integration, task queuing, robot traffic management in narrow spaces, and route optimization between sectors. To reduce risk, we introduced the robots in one production area first and expanded the system across the plant only after the process had been validated.

As a result, BORG Automotive gained a more predictable material flow, higher internal transport throughput, and full traceability of deliveries. In the areas served by the robots, forklift and pallet truck traffic has been completely eliminated, and warehouse staff gained time for tasks that directly support production.

Statistician

Analysis of data from mobile robots and IoT devices

Supervisor

Comprehensive handling of transportation processes