How many totes can the storage system track?

The documented layout stores about 1,260 plastic boxes with QR codes. Your count depends on tray density, box size, and tower configuration.

Can one fleet handle light and heavy payloads?

The case used custom top modules for lift handoffs and separate heavy-payload modules for larger loads. Mixed fleets are common when lines feed different carton sizes.

What throughput should planners expect?

Leadership cites roughly 1,000 items per shift after automation. Validate against your SKU count, shift length, and distance between lifts and lines.

How should a US manufacturer finance this stack?

The public case provides no pricing. Service Robot Co. can compare AMR and automation leasing or purchase once lifts, software, and service scope are defined.

a European cable-harness and electromechanical assembly manufacturer

How a Cable-Harness Plant Cut Intralogistics Errors Below 0.5% With AMRs

Q: Do AMRs need vertical lifts to hit sub-1% errors?

This plant combined lifts, QR tracking, put-to-light, and AMRs. US sites with single-floor storage may need a different architecture to reach similar accuracy.

A European cable-harness maker paired AMRs with vertical lifts and QR-tracked totes, processing about 1,000 items per shift with errors under 0.5%.

<0.5%
Error rate: ~1,000
Items per shift: 1,260
Tracked boxes: 5
Lift towers

Based on a documented real-world deployment. Figures are from public reporting; the organization is not named.

Technicians assemble cable harnesses along rows of workstations in a bright factory. — Photo: SINOSTEEL STAINLESS STEEL PIPE

Multi-Floor Material Flow Created Errors

A European cable-harness and electromechanical assembly manufacturer serves electrical engineering, white goods, and textile machinery customers. Material flow had been spread across several floors with decentralized storage.

Manual picking and carrying slowed line feeding, increased physical strain, and left room for mistakes. Leadership wanted faster, more accurate intralogistics without simply adding headcount ahead of growth.

Decentralized storage across multiple floors
Manual picks and long walk times
Physical strain on assembly feeders
Errors from manual data entry and touches

A worker carries plastic bins through a factory corridor between floors. — Photo: Sinan KRIYA

AMRs Meet Vertical Lifts and QR Tracking

Tall storage racks line an industrial intralogistics aisle. — Photo: Tiger Lily

An integrator deployed a fleet of medium-payload autonomous mobile robots with task-specific top modules, including custom interfaces for vertical lift transfers and heavier Nord Modules payloads.

Five vertical lift towers with hundreds of trays store about 1,260 plastic boxes tracked by QR codes to eliminate manual data entry. Two towers use customized trays for standard small load carrier boxes so robots can interact autonomously.

Put-to-light guidance and hands-free transfers between lifts and production lines replaced much of the walking and waiting. Trays are staged before robots arrive to cut dwell time on the floor.

Integrate AMRs with vertical lift modules
QR-track every tote in the storage system
Use custom and heavy-payload top modules
Add put-to-light for pick confirmation

About 1,000 Items per Shift With Fewer Mistakes

The plant now processes around 1,000 items per shift while fewer people stay tied to picking and in-process handling. Walk time and manual touches gave way to scanning and supervision.

Combined automation pulled the intralogistics error rate below 0.5 percent according to the published case. The faster rhythm supports deliveries across the company’s European customer base.

The source does not provide payback months, headcount reductions, or dollar savings. Treat the error and throughput figures as site-reported outcomes from one integrator-led deployment.

What US Assembly Plants Can Copy

Supervisors review production metrics during a floor walkthrough. — Photo: EqualStock IN

Service Robot Co. did not run this deployment. It shows how AMRs plus vertical storage can tighten multi-floor feeding for high-mix cable and electromechanical work.

Service Robot Co. gives US businesses one partner for selection, financing, deployment, integration, training, and nationwide service across cleaning, delivery, security, and warehouse robots. QR discipline and lift handoffs should be scoped in a site assessment before lease or purchase terms are set.

When error rates above half a percent are tied to walk-and-wait picking, pairing AMRs with vertical lifts may beat adding another manual staging aisle.

Frequently asked questions