New Energy Industry-Flexible Material Distribution System

Client：A well-known manufacturer of electric drive systems for new energy vehicles

Industry：New Energy / Auto Parts

Challenge：

The electric drive production line must accommodate various models and diverse materials. Manual material preparation proves inefficient and error-prone, resulting in frequent production line shutdowns .

Traditional material racks occupy excessive space, with warehouses located far from production lines, forcing material handlers to make frequent trips—a major bottleneck for production efficiency.

The system cannot meet the flexible production requirements of 'small batches, multiple batches', and the lengthy line changeover time hinders capacity ramp-up.

Sunntol's solution:

Designed and deployed a flexible material distribution system centered on smart material towers and illuminated picking shelves.

A supermarket-style material buffer zone is set up at the production line, and the material tower is responsible for the automatic supply of high-frequency consumption materials.

The illuminated shelf system synchronizes with production orders, allowing pickers to efficiently complete material preparation by following light signals, ensuring 'materials to personnel' delivery.

The system is modularized, allowing flexible adjustments to layout and material storage strategies according to production plans.

Results and Influence:

The efficiency of material preparation and picking is increased by more than 40%, and the picking error rate is reduced to less than 0.1%.

The production line change time is shortened by 35% on average, which greatly improves the production flexibility.

Material delivery workers' walking distance is reduced by 60%, allowing them to focus on high-value tasks.

Customer Testimony:

* "Suntown's flexible distribution system is the lifeblood of our digital workshop. It resolves the core pain point of multi-variety co-line production, achieving both efficiency and flexibility." — Production Operations Director

Learn About Flexible Material Handling Solutions