Helpers during ghost hours.

Their work is actually all about ... working. Lista AG from Erlen in eastern Switzerland specialises in warehouse and factory equipment. The company is known for its workstations, workbenches, drawer and shelving systems. They are used by the bicycle mechanic around the corner as well as in aircraft maintenance at Zurich Airport.

But factories are changing: the traditional workshop is increasingly transforming into a smart factory. Automation and the optimisation of goods flows play a central role in this. ‘The logical consequence for us is that we have added driverless transport systems to our product range - so-called AGVs,’ says Olaf Gleibe, Head of Product Management and Marketing at Lista.

More efficient intralogistics

AGVs (automated guided vehicles) are designed to make companies' intralogistics more efficient: they transport materials for assembly, workpieces for further processing and finished products to the warehouse. They travel on predefined routes and orientate themselves using laser scanning technology. They receive orders either manually from a terminal or directly via an ERP.

Once an order has been completed, the transport robot is ready with the material for the next one. This minimises costly waiting and downtimes during which production cannot take place.

Bystronic and AGVs: great potential

Thomas Dörig, Head of Solution Centre at Bystronic, sees great potential in the combination of Bystronic systems and Lista AGVs. ‘This is profitable wherever we can close gaps in the material flow,’ he says. In automated bending cells, for example, the regular removal of parts is particularly important: "The volume of a bent part is usually significantly higher than that of a flat sheet. In other words, a pallet with 100 flat sheets can easily become ten pallets as soon as the parts are bent." The ability to remove parts automatically therefore directly increases the time during which a bending cell can be operated autonomously.

AGVs can also serve as a link between Bystronic and third-party systems. ‘This is where cut or bent parts from Bystronic systems are transported for deburring or painting, for example,’ says Dörig. ‘The big advantage of the AGVs is their flexibility, because our customers' requirements are very different.’ Whether there is a lot of space or little, whether whole sheets or small parts need to be transported, whether manoeuvring is required close to the ground or at working height - there is a solution for all these requirements.

Standardised interfaces, simple integration

On the one hand, the integration of AGVs requires precisely defined, well-structured processes. On the other hand, interfaces are required - to an ERP and to other machines and systems. "The AGV doesn't just need to know its job. For example, it must also be able to access the loading zones of a machine and therefore communicate with its safety control system. Or with the building technology to trigger a door opening," says Dörig.

Integration usually runs smoothly. Bystronic can provide standardised interfaces. This makes interoperability easier the longer it goes on. This is also confirmed by Philipp Nef, Head of Smart Solutions at Lista:

Higher output, lower costs

Nef says: ‘The extent to which a company benefits from AGVs depends on the degree of automation - in other words, which manual activities are replaced by the automated guided vehicles.’ In general, however, productivity is sustainably increased by using AGVs: lean processes, fully automated production steps and ‘ghost shifts’ without any personnel increase output and reduce costs.

And that's not all. AGVs also have a rather unexpected advantage, as Olaf Gleibe reveals with a laugh: "Of course, you want to avoid an AGV encountering an obstacle on its route and having to take major detours. That's why it's always tiptop tidy in our company now!"