Automated AGV System for Material Transportation in Automotive Manufacturing Plants

ETEK has successfully deployed a large-scale AGV system for an automotive manufacturing and assembly plant in Vietnam, enabling a comprehensive digital transformation of internal material handling—from components and supplies to pallets and trolleys—helping the factory achieve its automation and operational optimization goals.

1. Customer Overview

The project was implemented for one of Vietnam’s leading automotive manufacturing and assembly enterprises. The company operates in the precision mechanical engineering sector and is on a full-scale modernization journey toward a globally standardized smart factory model.

2. Challenges Before AGV Implementation

Prior to adopting AGVs, the factory relied entirely on manual labor and traditional trolleys to transport materials, components, and finished products. Each area required a dedicated workforce for material handling, leading to inefficient resource utilization and higher operating costs.

Manual transportation also lacked stability—errors and delivery delays were common, especially during peak hours. Labor constraints such as working hours and shift breaks made it impossible for the legacy model to support continuous 24/7 production.

Moreover, a dense shop-floor environment increased the risk of collisions and workplace accidents. These factors collectively hindered productivity improvements and the development of an efficient, intelligent logistics system.

3. ETEK’s Comprehensive AGV Solution

ETEK delivered a diverse automated transport system using multiple AGV types, including:

• Latent AGVs – for component box transportation
• Pallet AGVs (FLMR) – for heavy-load pallet handling
• Tractor AGVs – for towing heavy trolleys within the factory

3.1. AGV Latent CT5 – Automated Carton Box Transportation

The AGV Latent CT5 uses V-SLAM navigation combined with QR codes, enabling flexible and precise movement throughout the factory. With a payload capacity of up to 1,500 kg and continuous operation for 6–8 hours, it efficiently collects and transports component boxes from the warehouse to areas such as SEQ and GA Lines. Operators simply define pick-up and drop-off points, and the AGV autonomously completes the entire process—significantly reducing manual handling and improving operational accuracy.

3.2. Pallet AGV – Automated Pallet Handling

This compact AGV supports loads of up to 1,000 kg and reaches speeds of up to 1,200 mm/s. It transports pallets containing components from staging areas to kitting stations and production lines, then automatically retrieves empty pallets and returns them to the warehouse. Equipped with warning lights and audible alarms, the AGV ensures safe operation while maintaining a continuous, accurate material flow without human intervention.

3.3. Tractor AGV – Trolley Towing

This solution optimizes the transport of heavy trolley assemblies (2,000–3,000 kg) across areas such as warehouses, Kitting, GA Lines, and SEQ. Using Visual SLAM guidance, the AGV operates independently without requiring complex infrastructure. Workers simply attach the trolleys, and the AGV autonomously tows them to delivery points—an ideal choice for improving continuity, reducing labor dependency, and modernizing internal logistics.

4. Thách thức triển khai và nỗ lực ETEK

During implementation, ETEK addressed multiple challenges, including complex factory layouts, numerous intersections, and strict stability requirements. The engineering team continuously monitored and fine-tuned the system, conducting multiple real-world testing cycles to ensure seamless integration with production processes.

5. Achieved Results

The AGV system deployed by ETEK delivered clear benefits:

• Significant reduction in labor costs for material transport
• Maximized operational productivity with 24/7 capability
• Continuous and accurate material flow
• Seamless integration with smart factory management systems

Conclusion

ETEK’s AGV solution not only automated internal transportation but also marked a solid step forward in the customer’s digital transformation journey. With proven deployment experience and a highly skilled engineering team, ETEK is ready to accompany manufacturers in building smart, efficient, and safe factories.