Future-Proof Manufacturing needed to modernize its material handling without pausing production. The facility runs 24/7, serving just-in-time automotive assembly lines. Any stoppage would cascade into millions in supplier penalties. Their existing manual tugger-and-forklift system was hitting its physical limits.
IntelliSyncs deployed collaborative robots and automated guided vehicles in a parallel-phased approach: new equipment was installed alongside existing workflows, tested during maintenance windows, and cut over incrementally. Cobots handled repetitive pick-and-place tasks while AGVs replaced forklift routes. The migration completed with zero production minutes lost.
Measurable impact, delivered
Every metric verified against baseline — not projections, production numbers.
Stack powering this deployment
The systems, platforms, and integrations that made this project possible.
“We didn’t believe zero-downtime was possible in a 24/7 facility. IntelliSyncs proved us wrong — and delivered 35% more throughput on top of it.”