HORIZONTAL APPLICATIONS

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INBOUND RECEIVING TO END OF AISLE

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In warehouses or distribution centers, pallets are moved from inbound docking to storage area several times per day. Usually, an operator transports one or several pallets from receiving to end of aisles where vertical lift trucks can store them in high racking. 

Robots Driven by BALYO can be used to replicate the path of manual drivers and complete long distance transports of pallets to end of aisles. Dedicated buffer areas can also be created throughout the warehouse where Driven by BALYO lift trucks will drop pallets that have to be stacked. 

The BALYO robot range allows our customers to automate the full process : pallet transfer using robotic pallet trucks and racking storage using autonomous reach trucks or VNA. 

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Intelligent pallet detection : This feature allows a robot to scan staging lanes using its safety laser, in order to detect and remove pallets from the zone. After a scan, if a pallet is detected, the information is sent by the robot to the BALYO Robot Manager that will trigger a pick mission. This robotic solution is fully autonomous and removes the need for a manual operator to trigger pallets removal.  

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INBOUND TO QUALITY CONTROL OR STAGING

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In operations such as cross-docking or manufacturing, pallets that are delivered to an inbound staging area, need to be moved throughout the facility to quality control or staging areas. These pallets are usually manually scanned and delivered to a determined area. 

Robots Driven by BALYO can increase efficiency in such operations using a barcode reader that can scan a pallet and determine the appropriate destination. This can be executed with or without the help of a WMS.

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Barcode Scanning : A BALYO robot can be equipped with a barcode scanner to read  an identification plate on a load. If there is no WMS/ERP system, the BALYO will compare the barcode to a pre-populated database to determine the drop location.

Alternatively,  you can also integrate the BALYO robot manager with a WMS system. In this case, the robot manager will receive instructions directly from the WMS/ERP which is taking over responsibility to assign pick and drop stations according to customer realtime needs. 

If an identification issue occurs, BALYO can determine a default dropping scenario to ensure operational continuity.

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INTER-BUILDING TRANSPORT

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Large warehouses and distribution centers face the challenge of long distance pallet transfers. Such materials flows consist in transferring loads from inbound, long- or short-term storage, to an outbound area. 

Manual operators are usually required to execute long distance travels and potentially have to go to the next movement empty handed.

With a Driven by BALYO robotic lift truck solution, you can avoid your operator painful and inefficient long distance operations. BALYO robots will take care of long horizontal movements between building or storage areas while your operators can work in a limited zone, being dedicated to added value tasks.

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MILKRUNS IN PRODUCTION

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A typical application for manual operators is driving tugger trucks pulling carts with materials to be delivered in multiple locations in a production facility. The Driven by BALYO solution automates the tugger routes removing the need for manual operators to drive in loops all day.

The Driven by BALYO tugger can pull up to 7000 kg carts loaded with goods. This type of application implies a high level of human/robot interactions (cobotics) to manage trailers or loads. The tugger missions can be triggered through an interface with a WMS/ERP software or through a push button that operators can use to assign a pre configured task to a robot. 

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Push Button Configuration : In any BALYO installation, missions are triggered by an event (pallet detection on conveyor, signal from palletizers…). If there is no WMS/ERP interface, triggers can be manually managed on the robot’s HMI, the Robot Manager screen or through robot features such as the intelligent pallet detection. Alternatively BALYO can offer a three button COMBOX where each button is assigned to a mission trigger, based on customer needs :  raw materials supply, finished goods removal, pallet transfer etc.

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END OF PRODUCTION

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When the manufacturing process is done, finished products need to be transported to another location such as a storage area, pallet wrappers, quality control, packaging or outbound staging areas. All of these logistic flows can be managed by a robotic lift truck Driven by BALYO.

BALYO robots can interface with every equipments along the manufacturing and shipping processes. At industrial customers, our robots usually transport pallets from: 

– production lines to palletizer

– palletizer to wrapping machine 

– wrapping machines to buffer or storage areas. 

The end of production is now fully automated without requiring additional operators but focussing employees on manufacturing operations. 

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Machine Interface : The Balyo Robot Manager can interface with machines via a COMBOX (communication module). The COMBOX will get a signal from a pallet detection sensor or the machine itself when a pallet is ready to be picked up. That signal will trigger a mission which will call for the next available robot to come pick up the pallet and drop it to the designated area.

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WORK IN PROGRESS GOODS

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During the manufacturing process, products have to be moved from a working cell to another. Usually managed by conveyor systems and/or manual lift trucks, it implies that production operators will be partly dedicated to handling tasks. Conveyors can automatically transport pallets but are complex to deploy and not scalable.

The Driven by BALYO robots are developed to manage tasks that do not generate value for the company. Keep your operations flexibility with a solution that adapts very easily to layout changes, thanks to a unique navigation technology. 

Upgrading from manual to robotic handling will allow your workforce to be focused on manufacturing operations and bring activity growth opportunities.

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ERP interfacing : Interfaced with your manufacturing infrastructures and your ERP software, the BALYO solution can now improve your daily operations. When a pallet is ready to be moved to another working cell, your ERP sends a message to our Robot Manager that calls a robot to proceed.

The development of this BALYO/ERP interface is made by our commissioning team in collaboration with your IT department. 

07

EMPTY PALLET REMOVAL​

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Within a manufacturing cell, pallets transporting materials come in and need to be removed or stored once they have been used, which is not a priority task for production operators. 

Robotic lift trucks have the best return on investment when they are continuously working. 

A robot can be used to not only drop off material pallets but also to pick up and remove empty pallets from the production area. Managing this low added value task will save operators time and allow them to focus on the manufacturing operations. This type of robotized applications can result in a growth of activities with the same quantity of employees. 

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Palletizers : The BALYO Robot Manager can interface with an equipment like a palletizer to trigger missions.  BALYO can set up a system where a robot notifies a successful drop off of an empty pallet, so the palletizer can start its own work. The palletizer can also notifies that a pallet is ready to be picked up, then the robotic lift truck will manage. 

Thinking about upgrading?

Looking for some advises or some ways to maximize your ROI and be more efficient? our experts are there to answer to your questions.

REQUEST A POC (PROOF OF CONCEPT) TO BALYO

DESCRIBE YOUR SPECIFICATIONS

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5 key points to take into account while writing your specifications

Here is a short list of advices you need to review before writing your robotic project specifications. Don’t miss it!

CHOOSE A ROBOTIC SUPPLIER

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5 things to check before choosing your supplier

Before making your final decision, here is a list of advises to choose a supplier based on your current needs, but not only!

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Request a demo at BALYO

You now know a little more about the players and technologies available, your robotic project takes shape and you want to see a robotic lift trucks in real life? It’s possible! Fill out this short form and make an appointment directly with one of our experts in one of our showrooms.

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Request a Proof Of Concept in your facility

You have been in touch with one of our experts and need to see what a robot is capable of in your facility? It’s possible! Complete this short form and book an appointment!

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How do you generate savings? Tricks to calculate your ROI

Customers usually compare the cost of purchasing a robotic system with the drivers salary which represents 80% of a pallet movement cost. This is a start, but this is not the only element to take into account.

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Estimate your cost savings

Today you can easily automate more than 80% of warehouse applications. Our smart and free simulator, MyCashBox, helps you to find your automation opportunities and get a quick overview of your potential savings.

YOUR FIRST ROBOT INSTALLATION

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Let’s start with BALYO

Now that you’ve ordered your BALYO robotic solution, the whole project team will be focused on delivering the targeted performance level.
BALYO teams will drive your success by providing you with all the performance analysis you need (Statistic Tool) to understand how your robots and human operators behave.
All along your journey, we will recommend the best optimizations to successfully implement your robotized processes.

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Your Project Kick-Off

Kick-Off
The Kick-Off is the first step of the BALYO Project Management Process. Prior to the Kick-Off meeting, our project manager will prepare a list of documents including the application-specific customer specifications, technical specifications, the project risk analysis & the project planning. Then, these documents and milestones are presented to you during the Kick-Off meeting.

Before your installation 
After an internal validation of the Software and Hardware bricks needed for your robotic project, the manufacturing process starts. In parallel, our project manager helps you prepare everything before robot commissioning: IT infrastructure & Software interfaces readiness, risk analysis recommendations implemented, site adaptations made, etc. Once the robots are produced, we perform an internal commissioning to test and validate all the safety and functional features before shipping the autonomous forklifts to your facility. All the results are obviously shared with you.

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Installation phase

Once the robots are delivered to your facility, the job of the field engineer in charge of installing your BALYO system starts: mapping of the building, routes design, pick & drop points design, testing etc.
During this phase, we validate all functionalities with you, as well as safety and interfaces tests/reports in real conditions. We also train your teams to work alongside robots in a new cobotic environment. The ramp-up of your installation is ensured by measuring performances all along the process until the handover milestone, where you officially take the lead on your robotic system!

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HandOver

The handover formalizes transfer possession and risk from BALYO or its partners to the customer, meaning the system can be run without the presence of BALYO or its partners. The handover may contain “non-blocking open points” which will be dealt with in a final fixes phase. A non-blocking open point is an issue which does not hinder the system to achieve its contractual performance.

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Final Acceptance

The purpose of the final fixes phase is to close open points raised during the handover. When the robotic system is fully compliant to its specifications, the Final Acceptance is signed by all parties.

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Maintenance

Now your robots are fully operational, your main contact will be the service team. Organized by level of maintenance actions (base truck, hardware, software), our group of experts will support you whatever the issue is, ensuring continuity of your operations at the expected level of performance.

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Performance

Thanks to the BALYO Statistics Tool, you can track the performance of your system. Based on efficiency standards such as OEE or PackML data, our monitoring tool gives you the ability to follow and optimize your installation on a daily basis.

YOUR NEXT DEPLOYMENTS

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Your future needs

Usually, customers start their robotic investments with an installation of 3 robots (average). But keep in mind our solution is designed to scale your operations up! After your first deployment, our experts are available to think about your future optimizations and new robotized material flows.
For example, after having automated supplies and removals of your production line, the next step can be to automate the vertical storage of your finished goods. Don’t forget, Robotics is a journey.

QUESTIONS TO ASK YOURSELF

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Evaluate market players and technology

Before investing your time in a robotic project, it is important to understand what are the trends of the material handling and AGV markets. Get an overview of the AGV player typologies and technologies by downloading our white paper.

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What applications can you cover ?

You’re thinking about a specific application for your future robots? Have a quick review of all the material flows our technology can robotize with a incredible product range.

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How a robotic project is priced?

This is the question our customers always ask first! As robots’ deployment requires an important investment from your company, it is mandatory for you to understand how a robotic project is priced.

Here is some key information we would like to share to help you out!