Autonomous mobile robots in intralogistics

A leading European TV manufacturer is automating its internal material transport using autonomous mobile robots (AMRs). At its plant in Gorzów Wielkopolski, a fleet of 22 AMRs handles the flow of materials between the warehouse and the assembly lines. The result: stable processes, increased safety, and more efficient intralogistics.

Manual transport as part of existing processes

This implementation is one of the largest AMR deployments in European intralogistics. TPV Displays Polska has been pursuing a clear automation strategy for years. Before automation, internal transport was heavily reliant on staff and manual processes. Employees moved TV panels and materials using electric carts - a time-consuming, physically demanding task that was prone to delays.

Key challenges:

High manual effort combined with physically demanding tasks
Uneven material flow and a lack of transparency in internal transport processes
Limited flexibility in adapting the production and layout concept
Growing shortage of skilled workers in logistics and production

The solution: Automated material handling using autonomous mobile robots

TPV Displays Polska was looking for a smart automation solution that is efficient, safe, and scalable. With the implementation of 22 AMRs, the entire internal transport process is now fully automated. Mobile robots navigate autonomously through dynamic production environments and reliably handle key transport and logistics tasks.

Automated transport systems in the company perform the following tasks:

Automated material handling of TV panels and components from the warehouse to ten assembly lines
Autonomous return of empty packaging and residual materials to the waste sorting area
Efficient route planning that optimizes material flow, prioritizes delivery orders, and reduces unnecessary trips
Safe and smart navigation in complex environments, working side by side with employees

Synergies between stationary and mobile robots

Industrial robots for precise handling

Even before the introduction of mobile robots, TPV Displays Polska was already working with over 40 high-performance six-axis KUKA industrial robots, including KR QUANTEC I Model KR 120 R3100-2 and the KR IONTEC I Model KR 70 R2100.

KUKA stationary robots safely handle TV displays in internal material transport. — The KR IONTEC robot handles displays with precision and offers a high degree of flexibility in automation.

Flexible intralogistics with AMRs

The 22 KMP 1500P autonomous mobile robots complement the stationary KUKA industrial robots to form an integrated system that supplies materials, intelligently controls intralogistics routes, and reduces bottlenecks. Their sensor technology and autonomous navigation ensure efficient and safe transport in intralogistics. The mobile platforms offer the payload capacity and precision required by TPV Displays Polska and are designed for dynamic production environments.

KUKA KMP?1500P autonomous mobile robots use advanced sensors and navigation technologies for efficient and safe transport. — These autonomous mobile platforms can be seamlessly integrated into existing systems and environments, thereby supporting cost-effective, future-proof intralogistics that offer companies tailored benefits.

The combination of stationary robots and AMRs improves the efficiency of supply to assembly lines, increases flexibility, and integrates material flow and storage into a high-performance integrated system.

Grzegorz Benda, Technical Director at TPV Displays Polska

Autonomous transport of empty containers and residual materials in intralogistics — Autonomous platforms independently identify obstacles along the route and navigate around them autonomously.

Smart software control for all internal logistics

At TPV Displays Polska, the integration of mobile robots was completed by Saicon, an integrator with many years of experience in industrial automation. The Saicon team handled the complete system integration, commissioning, and validation of the solution.

As part of the project, the AMR fleet - controlled via AMR.Fleet Fleet Manager – connected to the plant’s higher-level systems and supplemented by specially developed algorithms for controlling internal logistics.

KUKA autonomous mobile robots use Li?ion batteries with inductive charging to remain operational around the clock. — Thanks to inductive charging, these mobile robots operate continuously 24/7 without scheduled charging breaks - making them an essential means of transport for critical tasks, such as those in a warehouse.

Key responsibilities of the fleet manager:

Automatically assigns transport orders
Monitors the AMR fleet in real time
Sets priorities for transport tasks

Intelligently manages internal access rights
Optimizes utilization and routes
Enables rapid recovery in the event of disruptions

The entire system is designed for continuous, stable 24/7 operation and includes both the mobile robots and the associated IT infrastructure with servers, a software stack, and active backup, enabling uninterrupted operation and rapid recovery in the event of a failure. The AMRs dynamically adapt their driving behavior to employees’ workflows, detect and avoid obstacles, prioritize right-of-way, and optimize fleet utilization.

The status of the entire mobile robot fleet is available in real time, while the collected process data supports targeted analysis and optimization of intralogistics processes in production.

The key challenge was seamlessly integrating the new technology into existing TPV processes. Our solution fully automated the intralogistics and made them reliably predictable. An additional safety audit confirming CE compliance verifies efficiency and operational safety.

?ukasz Sobczak, Head of the Software Development Team at Saicon

KUKA KMP?1500P autonomous mobile robots enable safe and flexible intralogistics using SLAM?based navigation in complex production and logistics environments. — Autonomous mobile robots (AMRs) have established themselves as a key mode of transport in modern intralogistics.

This implementation demonstrates that autonomous mobile robots are already increasing production stability today - through reliable processes, greater transparency in material flow, and better management of intralogistics complexity.

Mateusz Nowakowski, AMR Business Developer at KUKA Polska

Safe, autonomously operating automated guided vehicles enable fast material transport between assembly stations. — Safe, autonomous platforms enable the rapid transport of materials between assembly stations and operate independently within dynamic production processes - an optimal solution for moving various goods.

Key takeaways: Automation creates transparency, stability, and future-proofing

The introduction of autonomous mobile robots at TPV Displays Polska demonstrates how modern companies can transform their internal logistics processes. A scalable AMR fleet, complemented by intelligent software and stationary robotics, forms the foundation for:

Reliable material flows through stable, automated transport
Higher productivity thanks to reduced downtime
Clearly structured intralogistics through centralized control
Sustainable growth through scalable solutions with controlled costs

Automated intralogistics is thus a key enabler for efficient, safe, and flexible manufacturing.

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Autonomous mobile robots in intralogistics

Manual transport as part of existing processes

The solution: Automated material handling using autonomous mobile robots

Automated transport systems in the company perform the following tasks:

Automated material handling of TV panels and components from the warehouse to ten assembly lines

Autonomous return of empty packaging and residual materials to the waste sorting area

Efficient route planning that optimizes material flow, prioritizes delivery orders, and reduces unnecessary trips

Safe and smart navigation in complex environments, working side by side with employees