From manual tugger trains to autonomous logistics
Our customer: Futaba Czech s.r.o.
Futaba Czech s.r.o. is part of the global Futaba Industrial Co., Ltd. group, one of the leading suppliers to the automotive industry. The Havlíčkův Brod plant specializes in stamping and welding metal parts used in millions of vehicles worldwide.
The company has long focused on efficient production, consistent quality, and modern technologies that contribute to more sustainable operations and greater manufacturing safety.
From planning to full autonomous logistics in two months
At Futaba Czech s.r.o., together with our partners, we implemented a fully automated internal logistics system in just two months, based on six Autonomous Mobile Robots (AMR).
The project was initiated in response to growing demands for supplying a total of 21 production lines, which together produce more than ten million parts every month. Such high volumes place extreme requirements on accuracy, speed, and stability of logistics processes.
The original system, based on manual tugger trains, could no longer support further production growth. The goal was therefore to introduce a modern solution that would replace manual transport, ensure smooth operation even in shared zones with manual equipment, and create a stable logistics system ready for future expansion.
The project was the result of close collaboration between three companies, each contributing key expertise to the solution:
- Linde Material Handling – delivery and configuration of AMR vehicles and design of their integration into the plant’s existing infrastructure.
- AIMTEC – overarching logistics management through the WMS system, which has long coordinated warehouse and production processes at Futaba.
- Blumenbecker Prag – software and communication layer between WMS and AMR, control of robot operations, and their interaction with manual equipment.
Thanks to the combination of these competencies, a comprehensive system was created that enables robots to operate in the real plant environment, move safely in shared zones, and respond efficiently to the current needs of production.
Blumenbecker Prag’s role in the project
As a system integrator, we were responsible for ensuring that all parts of the project worked together as a single unit. Our solution forms the communication layer between the Warehouse Management System (WMS) and the AMR vehicles. The WMS decides what needs to be transported, from where, and to where. Our software logic translates these decisions into specific missions for the robots and simultaneously monitors their behavior in real-world operations.
The integration also included managing areas where AMR robots and manual equipment operate together. Here, we designed and implemented traffic light systems to ensure smooth and safe movement. Robots always have clear information on when to proceed and when to stop, while operators of manual vehicles can instantly see the current status. As a result, the entire logistics flow is stable, predictable, and safe.
An integral part of our solution is the visualization interface. It allows real-time monitoring of robot positions, battery status, tasks in progress, and any service events. This fleet management capability ensures not only smooth operation but also the ability to respond quickly to changes or exceptional situations.
By enabling seamless communication between all systems, we have created a fully automated logistics process that can adapt to current production needs and support future growth.
Words from our specialist:
»Simply put, we act as an interpreter between the taxi dispatcher, who knows what needs to be transported and where, and the taxi drivers — in this case, the robotic vehicles.«
Customer quote:
»We produce around 10 million parts every month, which places high demands on logistics processes and manual work. That’s why we focused on increasing efficiency by introducing automation with AMR vehicles.«
Are you interested in our robotics solutions?
Contact us—we will be happy to advise you and provide you with a customized quote for your automation application.
Lenka Hudrlíková
Robotics Sales and Marketing Manager