The daily work on the production floor of a leading European TV manufacturer has changed significantly: Where employees once had to maneuver electric carts through the halls, today self-driving transport robots from KUKA take over this task. At the company’s site in Gorzów Wielkopolski, Poland, a fleet of 22 autonomous mobile robots ensures that materials are reliably transported between the warehouse and production – around the clock.

Automation brings stability to production

TPV Displays Polska is one of the leading manufacturers of television sets in Eu-rope. Numerous industrial robots are already in use in production. Before the automation of internal material transport, processes relied heavily on manual work. Employees moved TV panels and components through the production halls using electric carts – a time-consuming and physically demanding task. At the same time, material flow was uneven, difficult to plan, and only limited in its flexibility to adapt to changing production requirements.

“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, Technischer Direktor at TPV Displays Polska.

Automated material transport with autonomous robots

With the introduction of 22 autonomous mobile robots, internal transport has now been fully automated. The self-driving robots move independently through the production environment and take on key tasks: They transport TV panels and components from the warehouse to ten assembly lines, return empty packaging, and continuously optimize their routes. The robots work safely alongside employees and relieve them of physically demanding tasks.

A coordinated interaction between robots

Even before the introduction of mobile robots, the company relied on stationary industrial robots – meaning robots that are permanently anchored to the factory floor. Today, both systems work together to ensure a reliable supply to production. “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,”
says Grzegorz Benda, Technical Director at TPV Displays Polska.

Smart software ensures predictable processes

The integration of the mobile robots was carried out by the automation specialist Saicon. A central software system controls the entire robot fleet, assigns transport orders, monitors processes in real time, and optimizes routes as well as utilization. Thanks to inductive charging, the robots operate almost continuously in 24/7 mode. “The key challenge was seamlessly integrating the new technology into existing TPV processes. Our solution fully automated the intralogistics and made them reliably predictable”, explains Łukasz Sobczak, Head of the Software Development Team at Saicon.

Greater transparency and future readiness

The status of the entire robot fleet can be monitored at all times. The collected data helps to analyze processes and continuously improve operations. At the same time, the system is designed to flexibly adapt to future requirements.

From KUKA’s perspective, the project also demonstrates the potential of this technology: “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”, says Mateusz Nowakowski, AMR Business Developer at KUKA Polska.