Located at the customer's (a top tech brand in China) manufacturing base in Wuhan, this project covers approximately 35,000 square meters and manages the entire intelligent warehousing process of the finished air conditioners. Wayzim constructed a super warehousing hub featuring a lights-out AS/RS, AMR fleets, and a high-speed RGV backbone for the customer.
The solution integrates an automated palletizing system, AMR fleets for flexible handling, a high-speed RGV backbone, a stacker crane AS/RS, a robotic leak detection system, and an intelligent sorting system. In conjunction with Wayzim's in-house developed WMS, WCS, GRCS, and 3DMS (3D digital twin warehousing software system), the solution supports unified dispatching and a fully unmanned workflow from production completion to outbound shipping.
Air conditioners are large in size and come in a wide range of models. When production ramps up during peak seasons, conventional warehouses are quickly overwhelmed.
Massive order surges during e‑commerce shopping festivals far exceed the capacity of manual picking and handling.
The conditioning and leak testing stages rely heavily on manual labor, making errors untraceable and posing substantial after-sales risks.
Step 1: Lights-out AS/RS–Maximize Storage with Vertical Space
The AS/RS, exceeding 20 meters in height, provides 15,344 pallet storage locations. Finished air conditioners are neatly stacked like a “steel forest”, maximizing space utilization.
Step 2: AMR Fleets & A High-speed RGV Backbone—Autonomous Goods Transportation
Inbound operation: Automatic palletizing, millisecond-speed visual inspection, and automatic data binding.
Handling: Large-scale AMR fleets allow “goods-to-person” operations, replacing manual cross-warehouse handling.
Transport: The looped high-speed RGV backbone connects inbound, cross-docking, and outbound areas, serving as an internal metro-like transit system.
Step 3: Automatic Leak Testing & Visual Recognition—Quality Assurance
Each finished product passes through the automatic leak testing station and the visual recognition system. This solution supports millisecond-level testing and data binding and full closed-loop quality traceability throughout production, warehousing, and distribution.
Step 4: Deploying a Digital Brain for the Warehouse
WMS and WCS: Dynamic location allocation, batch management, and First In, First Out (FIFO) strategy.
GRCS: AMR Fleet dispatching, path planning, and automated traffic management.
3DMS: Real-time mirror of the physical warehouse, fault alarm, and one-click positioning.
01 Space doubled: The 20 m high AS/RS delivers far superior vertical space utilization compared with the conventional storage system.
02 Efficiency boost: Full-process automated collaboration allows a peak daily outbound volume of 90,000 units, with inbound/outbound throughput exceeding 600 pallets per hour.
03 Full traceability: Automatic leak testing, visual recognition, and full-process data binding eliminate human errors.
04 Dual cost reduction: The “lights-out” operation minimizes the reliance on manual labor, reducing both energy consumption and labor costs.
05 High operational flexibility: The solution supports multiple modes, including cross-docking for direct delivery, ensuring smooth handling even during promotional events.
Summary
Warehousing is no longer a production bottleneck, but a delivery accelerator. Wayzim has built an “express throughway” from production to distribution for the smart home appliance industry by integrating the lights-out warehouse, AMR fleets, a high-speed RGV backbone, and the digital brain.
Moving forward, this integrated intelligent manufacturing and logistics solution will be deployed in more factories, allowing enterprises to embrace a new warehousing model featuring unmanned workflows, high efficiency, and full traceability.
We look forward to your comments: https://www.wayzim.com/en/cooperation
