Project Overview
SAIC Motor is one of China's major automotive manufacturers. Its automotive wiring harness factory in Jining, Shandong serves as an important component production base responsible for the development, manufacturing, and supply of complete-vehicle wiring harnesses.
Wiring harness manufacturing presents significant logistics challenges due to the large number of SKUs, major differences in material specifications, and the complexity of warehousing and production-line distribution.
To support the factory's capacity expansion and lean production requirements, Anhui Ruiyou designed and implemented a comprehensive smart logistics solution covering the entire material flow process.
With a total project area of approximately 12,000 m², the solution fully utilizes both floor space and overhead space within the facility. It covers raw material unpacking and picking, automated high-bay storage, semi-finished product storage, automated conveying, and AGV-based production-line delivery.
Multiple automated warehouses located across different factory buildings are interconnected to create an integrated intelligent logistics network, significantly improving logistics efficiency and factory management capabilities.
Our Solution
To address the factory's requirements for high-volume SKU storage, cross-area material transportation, and accurate production-line delivery, Anhui Ruiyou provided a customized solution covering logistics planning, simulation, system integration, and final implementation.
High-Density Automated Storage System
Multiple automated warehouses were designed for both raw materials and semi-finished products, allowing the factory to make extensive use of vertical space.
The system provides more than 38,920 storage locations and supports the storage of over 33,600 SKUs.
Material transportation routes between automated warehouses in different factory buildings are interconnected, creating a unified and coordinated storage network.
End-to-End Logistics Automation
The automated logistics system covers key operations including:
- Raw material unpacking and picking
- Automated conveyor transportation
- AGV-based intelligent material handling
- Automated delivery of selected materials to production lines
By replacing traditional manual handling and picking processes, the system enables automated material flow from warehouse receiving and storage through to production-line distribution.
Simulation-Based Planning and Optimization
Logistics simulation software was used to analyze material flow, conveyor capacity, route congestion, and the overall logistics layout before system deployment.
Through simulation and route optimization, the final logistics design was validated and refined to support a total system throughput of up to 2,088 operations per hour, meeting the complex material flow requirements of multiple interconnected automated warehouses.
Integrated Warehouse and Equipment Management
The project integrates the Warehouse Management System (WMS), Warehouse Control System (WCS), and logistics scheduling system.
The integrated platform provides unified inventory management across multiple automated warehouses, coordinated equipment operation, intelligent task allocation, and seamless data connectivity between warehousing and production.
Customer Benefits
Greater Storage Capacity in Limited Space
Through multi-level automated warehouse planning and efficient use of vertical space, the project provides more than 38,000 storage locations and accommodates over 33,000 SKUs within a total footprint of approximately 12,000 m².
This significantly increases storage capacity per square meter, maximizes the value of existing factory space, and reduces the amount of land required for warehousing.
Higher Logistics Efficiency
The deployment of automated unpacking and picking, conveyor systems, and AGV material handling significantly reduces manual intervention, operator workload, and picking errors.
With an overall system throughput of up to 2,088 operations per hour, the solution improves warehouse and logistics efficiency while supporting increased production capacity.
Complete Digital Visibility and Traceability
Inventory data, equipment operating status, and logistics task progress across multiple automated warehouses are managed through a unified digital platform.
Materials can be traced throughout the entire process from warehouse receiving to production-line delivery, while real-time inventory visibility provides accurate data support for production planning and material scheduling.
Accurate Just-in-Time Line Feeding
Optimized logistics routes and intelligent scheduling enable materials to move efficiently between multiple automated warehouses and factory buildings before being delivered accurately to the production line according to actual demand.
The system closely matches the production cycle of wiring harness manufacturing, reduces line-side material accumulation and production waiting time, ensures stable production operations, and shortens overall material turnover time.