Unlike "Greenfield" projects designed from scratch for automation, most industrial sites are "Brownfield" environments—facilities where humans, manual forklifts, and legacy processes coexist. These sites present unpredictable challenges, from irregular operator behavior to infrastructure limitations. Our recent deployment proved how an intelligent, human-centric autonomous forklift solution can overcome these hurdles.
In a system without full SI (System Integration), we empowered operators to call robots via tablets. However, we faced "Human Error" risks: accidental double-calls, premature cancellations, or damaged pallet placement.
The Solution: We overhauled the UI/UX based on deep User Task Analysis. We implemented a robust State-Machine Process that aligns with the operator's mental model. This prevents "system freezing" from unintended inputs and ensures the robot remains resilient against erratic human commands.
At the unloading area (a 4x6 pallet grid), the robot’s workspace often overlapped with manual forklift paths. Obstacles placed in the robot's intended path caused navigation stalls and positioning errors.
The Solution: We deployed a Real-time Spatial Perception & Visibility System. By integrating a high-visibility Fleet Management System (FMS) display on the warehouse floor, we provided manual operators with a "shared mental map" of the robot’s status and intent. This enhanced situational awareness minimized interference and maximized collaborative efficiency.
The transit route between buildings introduced high risk due to pedestrian crossings.
The Solution: We applied Context-Aware Safety Protocols. The robot automatically reduces speed to a conservative "caution mode" in designated zones and utilizes enhanced sensory alerts—including high-intensity Blue Lights and frequency-tuned acoustic warnings—tailored to the noisy factory environment.
The client chose us over traditional, rigid automation for two reasons:
Infrastructure-Light Deployment: No complex floor modifications or expensive permanent barriers required.
Operational Flexibility: Our system allows for the dynamic use of space where humans and robots work side-by-side, unlike "black-box" automation that locks down the floor.
Following our commissioning completion on September 12, the client achieved a significant milestone: the retirement of one full-time forklift operator by October 1. By replacing manual labor with our autonomous forklift
solution, the client realized a full ROI within a single year, proving that human-centric robot design is the fastest path to logistics modernization.