Shuttle Cart Warehouse System for Smarter Material Handling in Automotive Production

Summary

UB deployed a warehouse management system integrating 4-way pallet shuttles, vertical lifts, and barcode tracking to automate material movement. The system improves throughput, safety, and space utilization through FIFO/FILO logic and real-time communication with WCS.

Operational Challenges

• Manual transfers created congestion and delays in material movement.

• Poor layout efficiency reduced usable storage capacity.

• Limited tracking accuracy led to occasional material mix-ups.

Solution Highlights

• Implemented a shuttle-cart-based warehouse system with 4-way pallet shuttles, vertical lifts, and high-density racking.

• Integrated barcode identification for automatic material tracking and validation.

• Enabled real-time communication between warehouse control (WCS) and upstream systems.

• Configurable FIFO/FILO flow logic for optimized space utilization.

Results

Picking Time Reduced by 40% through automation.

Storage Efficiency Increased utilization by 20%.

Operational Safety Improved with sensor-based controls and compliance standards.