Smart AGV Queue & Fleet Management via Tablet

The Requirement: A Tier 1 automotive parts manufacturer required a comprehensive fleet management system for their Autonomous Guided Vehicles (AGVs) on the production floor. The core operational needs were divided into two main flows:

  1. Finish Good (FG) Handling: Operators finish assembling products and use a physical remote to call an AGV to transport the FG to the warehouse.
  2. Material Preparation: When raw materials are depleted, operators trigger an AGV via remote to bring empty boxes to the stock room. The stock preparation team needs a way to know exactly what parts to prepare, how many, and which station requested them before the AGV arrives.

The Challenge: The complexity lies in “Queue Management.” With limited AGVs and multiple production lines triggering remotes simultaneously, a robust Queue Dispatcher was required. Additionally, operators at the stock room are working against the clock. The Tablet UI needed to be highly intuitive, prioritizing the destination (Target Station) visibility, and required foolproof mechanisms, such as preventing operators from loading more than the AGV’s maximum capacity (15 boxes).

Solution & Architecture

WP Solution designed a modern System Architecture separating the queue logic (Backend) from the user interface (Frontend) to ensure a stable, real-time response system.

System Architecture Diagram

Technology Stack

  • Node-RED (Backend & Queue Dispatcher): Acts as the central brain. It receives signals from hardware remotes via PLC, handles the queue logic (FIFO/Priority), and dispatches commands to the AGV fleet and Tablet UI.
  • Vue.js + UIBuilder (Frontend & Tablet UI): A custom Web Application developed for stock operators. The UI focuses on large, readable Target Station numbers and includes real-time calculation logic that flashes red if the selected quantity exceeds the 15-box limit.
  • MySQL Database: Manages Station Master data, AMR tracking history, and System Configurations (e.g., battery thresholds for auto-charging).
  • Admin UI (Image Upload): A backend portal for admins to upload images of parts linked to Part Numbers. These images automatically display on the Tablet UI, helping operators pick the correct materials instantly.

Business Impact (Outcome)

  • ✅ Zero Confusion: Stock operators prepare materials with 100% accuracy thanks to the clear Tablet UI displaying large destination numbers and reference images for parts.
  • ✅ Optimized Workflow: The Queue Dispatcher efficiently routes AGVs for both FG drop-offs and Material pick-ups, eliminating traffic jams or unhandled requests from the production lines.
  • ✅ Error Prevention: The built-in UI safety checks (warning at >15 boxes) ensure AGVs are never overloaded, preventing potential material damage during transit.

Engineering Insight: When designing UIs for factory floor operators, avoiding visual clutter is critical. Removing redundant thumbnails and replacing them with massive “Target Station” numbers allows workers to scan, understand, and act instantly, drastically reducing human error and speeding up the fulfillment process.

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