The daily workflow on the production floor of a leading European TV manufacturer has evolved. Where employees once maneuvered manual electric carts through warehouse halls, today self-driving transport robots from KUKA automate the entire process. At the company’s manufacturing site in Gorzów Wielkopolski, Poland, a fleet of 22 autonomous mobile robots (AMRs) ensures reliable material handling between the warehouse and assembly lines around the clock.
Warehouse Automation Brings Stability to TV Production
TPV Displays Polska is a top-tier manufacturer of television sets in Europe. While numerous industrial robots already optimize their main production lines, internal material transport previously relied heavily on manual labor.
Employees used to move sensitive TV panels and electronic components through the facility using electric carts. This traditional method was time-consuming, physically demanding, and inefficient. Furthermore, the manual material flow was uneven, difficult to predict, and offered limited flexibility to adapt to dynamic factory production requirements.
Automated Material Transport with Autonomous Mobile Robots (AMRs)
With the strategic deployment of 22 autonomous mobile robots, internal factory logistics are now fully automated. These self-driving transport robots navigate independently through the dynamic production environment to execute mission-critical material handling tasks:
- Efficient Supply Chain: Robots transport TV panels and electronic components from the warehouse directly to ten active assembly lines.
- Reverse Logistics: The AMR fleet automatically returns empty packaging to the storage zones.
- Route Optimization: Intelligent software continuously calculates and updates the most efficient travel paths.
Furthermore, these advanced mobile robots work safely alongside human employees. This seamless human-robot collaboration significantly reduces workplace injuries by relieving staff of physically demanding and repetitive 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.
This underlines how automated material transport helps companies make their production processes more stable, efficient, and future‑proof.