This project traces back to the early stages of setup around 2019, with implementation work continuing into 2020. The client operated a multi-floor facility using a largely manual Automated Material Handling process. Across five floors, operators relied on trolleys and cargo lifts to move boxes weighing between 10 to 30 kg. Each floor required dedicated manpower to relocate pallets, transfer boxes manually, and wrap full pallets before moving them to another level. Over time, space constraints, heavy manual work, and fragmented workflows began to strain daily operations.
Beyond cost, the real challenge was control and visibility. Box IDs and quantities were frequently recorded incorrectly, items were difficult to locate, and operators spent excessive time searching across floors. Manual handling also introduced safety risks, including musculoskeletal injuries. With multiple testers and operators working in parallel and no system-level tracking, human error became unavoidable. The client was especially concerned about equipment downtime and system stability, knowing that any disruption would directly impact production.
The most difficult decision was whether the investment in automation would truly justify the results. Reliability was non-negotiable, which led to extensive discussions and evaluations. It took nearly two to three years to finalize the design and align on a solution built around proven, mature technology. Factronics approached the project by first identifying the root issues, then selecting an overhead conveyor solution that could resolve space limitations without disrupting existing machine operations. The final system integrated spiral lifters connecting all five floors, overhead conveyors, drop points, and lifters to create a continuous and organized flow.
Execution was not without challenges. During the MCO period, manpower limitations and material shortages caused schedule pressure and required tight weekly planning to keep work on track. Despite these constraints, careful coordination and proactive planning prevented major setbacks. When the system went live, the change was immediate. Production areas became visibly more organized, with pallets and trolleys no longer scattered across floors. Over time, system tracking reduced errors during loading and unloading, improved productivity, and significantly cut down time spent searching for boxes.
What made this project special was its complexity and collaborative nature. It involved coordinating multiple parties, managing first-time concepts, and navigating real-world constraints under challenging conditions. For the engineer involved, it was also a first exposure to this sector, making the experience both demanding and formative. The result was not just an automated system, but a safer, more reliable operation that the client could scale with confidence.
