Logistics simulation of an automated guided vehicle for material handling

Abstract

As customer demands become more complex and urgent, automating manufacturing processes is crucial for manufacturers to quickly develop and deliver new products, maximising profits by capitalising on demand fluctuations. Automated Guided Vehicles (AGVs) are popular for streamlining manufacturing lines, but traditional AGVs can't move between floors, challenging multi-level facilities. Advances in the Internet of Things (IoT) now allow AGVs to communicate with elevators, enabling seamless movement between floors and overcoming this limitation. The collaboration between STMicroelectronics Malta's key engineers and the University of Malta aimed to modernise processes through automation, expanding operational space for enhanced efficiency, productivity, and safety. The facility’s layout spans multiple floors, each crucial for the creation of microelectronic components. Cutting-edge technologies such as AGVs and ARVs streamline material flow, minimising manual intervention and enhancing workplace safety. Logistic simulations were developed to optimise material handling, guiding strategic decision-making for cost-effectiveness and efficiency. By identifying and eliminating bottlenecks, the project maximises throughput and operational efficiency. It was found that adding another laser-marking machine for the production of microchips increases the number of delayed trolleys at the first process in the basement but increases the utilisation of all basement processes. Furthermore, in the current set-up with only one laser marking machine, it was noted that there are no delayed trolleys in the basement but the process has a lower utilisation. Additionally, it was also found that utilising two AGVs one on the ground floor and the other on the first floor to perform 3 and 5 missions respectively was the most effective method for material handling. The reason is that this system had the highest useful AGV utilisation, the lowest amount of lift delays and a low AGV collection time. In summary, this project validates the efficacy of automation systems, displaying STMicroelectronics Malta's commitment to innovation. Insights gained will drive further advancements, fostering continuous improvement in microelectronics manufacturing.