For companies that operate manufacturing and logistics sites in Thailand and across the wider ASEAN region, automating in-plant material handling is no longer simply “something to look into” — it is becoming a management theme that determines competitiveness. Gradually rising labor costs, the chronic difficulty of securing personnel, and the operational flexibility required to run 24 hours a day with high-mix, low-volume production: the practical answer that solves all of these at once, and that is now being adopted at remarkable speed, is the forklift AGV/AMR, commonly known as the FMR (Forklift Mobile Robot). As an IT integrator specializing in the manufacturing and logistics industries in Thailand, TOMAS TECH provides end-to-end support for Hikrobot FMRs — from deployment design and host-system integration through to installation, commissioning and maintenance. This article gives a systematic, shop-floor-level explanation of how FMRs work, the product series available, how to read the specifications, the safety and navigation technologies involved, the scenarios they support, host-system integration, applicable industries and the deployment process. We hope it serves as a practical guide to selection and planning for production engineering, logistics and facilities teams considering the automation of pallet transport.

“We want to replace several manned forklifts, but we do not know which type to choose.” “Can rack put-away and retrieval also be automated?” “Can it integrate with our existing WMS or ERP?” The FMR provides an exceptionally broad range of answers to questions like these. From lightweight pallets with a rated load of 300kg to heavy loads of 3000kg, from floor stacking below 2m of lift height to high racks at 4.5m, and across storage formats as varied as ground stacking, beam racks, conveyors and drive-through racks — the FMR’s greatest strength is that it covers them all with dedicated series and extensive customization. Let us begin by looking at what an FMR is and how it is built.

What is a forklift AGV/AMR (FMR)? Overview and basic structure

The FMR (Forklift Mobile Robot) is a transport robot that performs unmanned, automated execution of the work traditionally handled by manned forklifts — pallet transport, stacking, and rack put-away and retrieval. AGVs and AMRs fall broadly into three types: tugger, low-profile (latent, lifting and conveyor types), and forklift. Among these, the FMR is defined above all by its ability to automatically lift and transport pallets and heavy loads. It requires no manual operation, dramatically improving both the safety and the efficiency of the work, while at the same time handling a wide variety of cargo and allowing flexible deployment and adjustment according to the logistics and manufacturing processes it serves.

It is worth clarifying the difference between AGV and AMR here as well. An AGV (Automatic Guided Vehicle) travels along a predetermined route by following a guidance medium laid on the floor, such as magnetic tape or a guide line. If a person is on the travel route, the vehicle stops and waits. An AMR (Autonomous Mobile Robot), by contrast, uses on-board lasers, sensors and cameras to recognize its surroundings, generates a virtual map of the site, and then calculates its own route to the destination on that map. If there is an obstacle or a person on the route, it can calculate an alternative route and continue traveling while avoiding it. Hikrobot FMRs are built on this AMR autonomous-travel technology and support multiple navigation methods including SLAM, enabling flexible operation with no need for physical guides or markers.

Mast lifting and forks — the basic load-handling mechanizm

Like a manned forklift, the FMR body consists of a front frame, a mast (gantry), fork legs and a fork assembly. Understanding the role of each makes the selection process and the specification reading described later far easier to follow.

• Front frame: the structure connecting the chassis and the mast, housing the main components inside — drive system, battery, electrical control and casters. This is the part that contains the FMR’s “brain” and “heart”.
• Mast (gantry): the lifting mechanizm used for stacking and unloading. It is made up of nested inner and outer frames in multiple stages; a hydraulic cylinder raises a sprocket, which moves the fork assembly up and down via a chain. This is what allows the forks to lift loads to high rack levels.
• Fork legs: the legs that support the load and house the wheels. The wider the legs are set, the greater the stability during lifting, preventing tip-over when a load is raised to a high position. By choosing a “wide leg” specification to suit the pallet type, plastic pallets placed directly on the ground can also be handled.
• Fork assembly: the main load-bearing component that physically supports the cargo. It comprises the fork frame, the forks and the backrest (not applicable to stackers). Fork length is determined by the length of the pallets to be transported, while fork width and the spacing between the two forks are matched to the dimensions of the pallet’s fork openings.

On Hikrobot FMRs, the fork specification can also be flexibly customized to match the pallets used on site. A wide range of options is available: adjustment of the fork distance to suit the pallet width, “wide legs” for plastic pallets on the ground, “mounted forks” for picking up loads from platforms, and “combined forks” for narrow load-handling clearances. This makes it possible to handle non-standard load carriers as well, including various pallets, totes, roll cages, soft packages, rolls and drums.

The challenges of manned forklifts — why automate?

To properly appreciate the value of introducing FMRs, it helps first to lay out the structural challenges inherent in manned forklift operations. At many manufacturing and logistics sites these issues are intertwined and accumulate as costs that are hard to see.

Safety risk — sites where people and vehicles mix

Forklift-related accidents are among the most common causes of serious injury in the manufacturing and logistics industries. Collisions with pedestrians, load collapse, entanglement when turning in confined spaces — as long as people and vehicles share the same space, the risk can never be reduced to zero. In sites with narrow aisles and mixed personnel in particular, this safety issue is a constant business risk. FMRs are equipped with 360° environmental perception, obstacle-avoidance lasers and fork-tip sensors; when a person or obstacle is detected they automatically decelerate, stop or avoid it, fundamentally improving safety in such mixed environments. In fact, a case in the automotive parts industry reports that “narrow-body forklifts solved the safety issues of a cramped site with mixed personnel.”

Recruitment and retention — hiring difficulties and skills transfer

Forklift operation is a licensed skilled occupation, and recruiting and training operators takes both time and money. In the ASEAN region too, transport work that is simple and repetitive yet physically demanding suffers from poor retention and is a breeding ground for chronic labor shortages. If employees are dissatisfied with the workload or their conditions, turnover does not stop and recruitment and training costs recur again and again. Introducing FMRs to automate simple transport and load handling reduces the burden on workers, improves job satisfaction and safety, and consequently contributes to retention as well. People can then be redeployed to higher value-added processes.

Variability in output and human error

When transport is done by people, throughput varies with fatigue and skill level. Overtime in busy periods, arranging relief staff, misdeliveries and damage caused by mistakes — there are many variables, and they reduce the accuracy of production planning. An FMR does not tire and maintains consistent performance, so transport capacity becomes standardized and productivity improves substantially. Because it executes programmed tasks autonomously and accurately, the frequency of human error is also dramatically reduced. With stable transport lead times, upstream and downstream processes become easier to plan as well.

Space efficiency and total cost

Manned forklifts require wide aisles for turning and visibility, and storage space is sacrificed accordingly. By choosing a narrow-body series or an omnidirectional series among the FMR range, aisle widths can be kept down and storage density increased. In one actual case, a combination of “AMR + high-bay warehouse” cut more than 5,000 m² of storage area, and in another, more than 60 workers were reduced across the whole plant. An initial investment is required, but when viewed on a total-cost basis that combines labor, space, safety and quality, the benefits of deployment are clearly apparent at most sites.

FMR product series in detail — four series and how to choose between them

Hikrobot FMRs comprise four main series that can be selected according to site requirements. A major distinguishing feature is that the broad range from 300kg to 3000kg rated load is covered by in-house designed vehicle bodies. Here we look in detail at the load capacity, lift height, speed, characteristics and applications of each series.

Omnidirectional Series

The Omnidirectional Series is a highly distinctive product line within the industry. It covers a rated load range of 300kg to 1400kg. By incorporating different types of steering wheels inside the chassis, omnidirectional movement is achieved across a variety of body sizes. This allows operation in minimal aisle widths and enables flexible routing including diagonal movement, curved travel and lateral movement. Because it simultaneously satisfies the conflicting demands of “high storage efficiency” and “narrow-aisle layout planning”, it has been adopted in industries such as 3C (computers, communications and consumer electronics), new energy, automotive parts and tobacco. It also supports stacking. It is the first candidate for sites aiming to achieve narrow aisles and high-density storage.

Stacking Series

The Stacking Series specializes in stacking and in put-away and retrieval on high racks. Rated load is 1000kg to 3000kg, and with customization the maximum lift height reaches 4.5m. A purpose-designed body thickness keeps the required operating aisle width down and maximizes storage space. Modularised components have high interchangeability, with up to 80% of parts shared across different scenarios, giving excellent maintainability as well. The entire series is CE certified, and it is the product group recommended as the core of a logistics solution. It suits sites pursuing vertical storage efficiency, such as beam racks and high-density storage.

Transport Series

The Transport Series is optimized for high-speed horizontal transport. Rated load is 1000kg to 3000kg and maximum travel speed reaches 2m/s. A lightweight body design carries a high-capacity battery, and selecting the battery according to actual demand keeps redundancy to a minimum. As with the Stacking Series, the purpose-designed body thickness keeps the operating aisle width down and increases storage space. It also supports environment contour navigation and texture navigation, making deployment and implementation straightforward. It is well suited to sites that prioritize throughput in inter-process transport and long-distance horizontal transport.

Reach-truck / Counterbalance Series

The Reach-truck / Counterbalance Series merges the design philosophies of both reach trucks and counterbalance forklifts into a uniquely designed body. It is used mainly in indoor transport scenarios such as field-type pallets, euro pallets and vehicles in narrow picking spaces. It is widely adopted in industries such as lithium batteries, beverages and home appliances. With versatile interfaces that make customization for non-standard load carriers straightforward — adjustable fork spacing, clamps and so on — it is one of the most universally applicable product lines in the FMR range. It handles a wide variety of pallets and supports high racks as well.

Main models in the FMR family and guideline lift heights and load capacities

The FMR family includes model types such as F1 (omnidirectional), F3 (transport), F4 (stacking), F5 (reach) and F6 (counterbalance). Representative models, together with guideline figures for their rated load and maximum lift height, are summarized below. These are maximum lift heights at rated load; lift height and supported load can be changed through customization.

• F1-300T: rated 300kg / mainly transport applications (not CE compliant)
• F1-500T: rated 500kg / omnidirectional, lightweight pallet transport
• F1-1000U: rated 600–1000kg / omnidirectional, guideline maximum lift height up to 3000mm
• F4-1000: rated 500–1000kg / stacking, customizable to a maximum lift height of 4500mm
• F3-1500: rated 1500kg / high-speed transport
• F5-1600: rated 1600kg / reach, supports high racks
• F4-2000 / F5-2000 / F6-2000: rated 2000kg / stacking, reach and counterbalance
• F3-3000: rated 3000kg / high-speed transport of heavy loads

The F1-300T is not CE compliant, and for the F1-500T there is currently no scheduled plan for CE certification (if required, it can be assessed individually, with a certification cycle of about 4 months); apart from these, all models meet CE requirements. Non-CE versions are also available for the CE-certified models; in the non-CE configuration the safety loop is removed and the navigation and obstacle-avoidance lasers are changed to domestically produced lasers. TOMAS TECH will propose the optimum model configuration according to the region of deployment and the applicable safety requirements.

How to read the main specifications — the logic of selection

When selecting an FMR, it is important to read the catalogue specifications by translating them into your own site conditions. This section explains the key specifications to check and the logic behind selecting on each of them.

Rated load (300–3000kg)

The rated load is the upper limit of the weight that can be transported safely. Identify the maximum weight of the pallets plus their contents that you need to move, and select a rated load with some margin. One point to watch is that the permissible load may decrease as lift height increases. When lifting heavy loads to high levels, the judgement must be based not simply on the maximum load but on “the supported load at that lift height”. Understand the weight distribution of the items to be transported (mainly lightweight pallets, or a mix including heavy loads) and, if necessary, consider combining several models from different series.

Maximum lift height (up to 4.5m)

The maximum lift height determines up to which rack level loads can be stored and retrieved. In the Stacking Series it can be customized up to 4.5m. As a guideline for selection, the FMR’s maximum lift height should be 200–300mm higher than the storage height of the topmost level of the target rack. Without this margin, there is a risk of scraping or striking the rack or the load when putting goods in or taking them out. The higher the lift height, the more the stability design of the legs (wide legs and the like) and weight constraints come into play, so lift height, load and body size should be considered as a set.

Travel speed (up to 2m/s)

The Transport Series supports high-speed transport at up to 2m/s, and the FMR range as a whole offers high-speed transport performance with a guideline maximum of 1.5m/s. Speed directly determines the number of transport cycles per unit of time (throughput), but faster is not automatically better. The effective speed that can safely be used varies with aisle width, the number of curves, the degree to which personnel are mixed in, and stopping-accuracy requirements. The key is to work backwards from the required takt time and transport distance to the necessary number of units and speed, and to design with congestion and traffic in mind.

Positioning accuracy and stopping accuracy

FMRs combine lasers with camera vision to achieve millimetre-level positioning accuracy. This stopping accuracy is especially important where the robot must coordinate with other equipment, such as rack put-away and retrieval or conveyor integration. If the robot cannot stop precisely at the defined position, the result is failed fork insertion or collapsed loads. At points requiring precise stopping, the floor gradient conditions described later also become stricter (a guideline of 0.01 or less), so accuracy requirements and infrastructure conditions must be treated as two sides of the same coin.

Safety and sensing technology — working alongside people with 360° perception

At the core of the FMR’s value is the ability to work safely in the same space as people. Hikrobot FMRs adopt a multi-layered safety design that combines several sensors.

• 360° environmental perception: detects the environment and objects all around the vehicle, preventing contact with people and obstacles before it happens. This is the foundation of safe and reliable operation.
• Obstacle-avoidance laser: as the main sensor, it scans the surroundings and detects objects appearing on the laser emission plane at ranges of up to 20m. After detection, it decides whether to decelerate, stop or avoid.
• Fork-tip sensors (tip anti-collision sensor and fork-tip laser): an infrared distance sensor at the fork tip prevents striking or interference when picking up a load (guideline detection range of 12cm at a height of 50mm).
• Pallet in-position detection: detects whether the forks are correctly inserted into the pallet, increasing the reliability of load handling.
• Bumper strip / tri-color light / blue light / speaker: physical cushioning plus status indication and warnings to those nearby, supporting collaborative operation with people.

Sensing also has its limits. The obstacle-avoidance laser cannot detect suspended objects or extremely low objects that lie outside the emission plane; detection performance degrades for transparent or highly reflective objects (glass, stainless steel and so on); and small objects below 60mm × 60mm are difficult to detect. Taking these characteristics into account, TOMAS TECH designs to minimize blind spots by combining measures such as suspended-object detection options and adjustment of laser mounting height, according to the shape of the site and the form of the loads. The battery is a lithium battery with good thermal stability that does not decompose below 300°C, and a BMS (battery management system) provides multi-layered protection against short circuits, overcurrent, overvoltage, overcharge, overdischarge, abnormal temperature and other conditions. If software protection fails, hardware protection engages to safeguard the battery.

Guidance and navigation technology — SLAM, contour and environment navigation

Navigation technology is what underpins the FMR’s autonomous travel. The principal guidance methods for AGVs and AMRs are magnetic guidance / line tracing, landmark methods (images and QR codes), and laser guidance (SLAM), each with different site requirements, advantages and disadvantages. Hikrobot FMRs offer the flexibility to combine these according to the site.

SLAM (simultaneous localisation and mapping)

SLAM (Simultaneous Localization and Mapping) is a technology in which a mobile unit performs self-localisation and environmental mapping at the same time, enabling autonomous travel. Its greatest advantage is that no physical guides or markers are needed, so the robot can travel autonomously even in complex layouts and changing environments. FMRs support map creation that fuses LSLAM (laser SLAM) and VSLAM (vision SLAM), and expert guidance is provided to raise quality throughout every stage of map building. After mapping, map quality is evaluated automatically, and the AMR is automatically scheduled to generate the evaluation results, so that the mapping work is reliably completed in a single pass.

Environment navigation and contour navigation

Environment Navigation performs real-time localisation and map building using a single-line laser radar as the main sensor, with models available for use with or without reflectors. Contour Navigation performs localisation and map building using a multi-line laser radar as the main sensor. The Transport Series supports environment contour navigation and texture navigation, making it easy to deploy. In real sites, “hybrid operation” — for example using SLAM in the main aisles and QR codes or line guidance in the storage zones — is often effective, and TOMAS TECH designs the optimum combination according to site conditions.

Supported scenarios — applications and evaluation points by storage format

FMRs support a wide variety of storage formats, but each scenario has its own evaluation points to check. Below we explain six representative scenarios and their key considerations.

1. Beam style racks (common)

This is the most common scenario. Check whether there is sufficient space to put loads in and take them out (including whether guide rails are present), the clearance between stored loads (a guideline of at least 100mm), the aisle width (200mm of buffer on each side), and whether the maximum lift height matches the storage height (lift height should be 200–300mm higher than the storage height). Safety considerations are also essential: oversized or misaligned loads, collisions with racks or other loads, and lowering the forks before exiting.

2. Conveyor integration (Conveyors, common)

Key points include verifying rack and pallet sizes (an in-position sensor is normally required) and coordination between the FMR and low-profile robots (LMR) — pallet detection is needed for pick-up and a composite map for drop-off, with clearances of 50mm on each side and 25mm front and rear. Also confirm that the conveyor end does not block the FMR’s travel path (that the vehicle body and the conveyor do not overlap in plan view).

3. Elevated platforms (common)

Pick-up positions should be managed by “position constraint plus identification”; hand-drawn line marking is not recommended. Check the clearance between load and rack, the navigation angle and safety distance, and whether loads are oversized or misaligned. For picking up loads from platforms, fork customizations such as mounted forks or combined forks are effective.

4. High density storage (common)

SLAM is used in the main aisles, combined with QR codes and line guidance in the storage zones. Check the clearance between loads (the width of the FMR plus the load, plus 100mm of buffer on each side), whether loads are oversized, and whether load height interferes with the laser emission plane. The design must maximize storage density while securing safety margins.

5. Drive-through racks (rare)

This is a relatively rare scenario, but check that the top and bottom surfaces of the loads are flat and undeformed, and confirm the aisle width (the width of the FMR plus the load, plus 100mm of buffer on each side). For this scenario, the F5 (reach) and F6 (counterbalance) are recommended. SLAM plus straight-line QR codes are used in the main aisles, and QR codes and line guidance in the storage zones.

6. Ground stack aisles (common)

SLAM is used in the main aisles, with QR codes and line guidance in the storage zones. Clearances between loads and racks are laid out according to the standard, and pick-up positions are managed by position constraint plus identification. This suits operations that make use of existing infrastructure such as racks or ground stacking. In all of these scenarios, the FMR has the strength of being able to pick up loads directly from the ground, but note that the pallets must be of the open-entry type.

Host-system integration — RCS-2000, iWMS and WCS

The true value of the FMR lies not only in the travel performance of the individual unit, but in working with host systems to optimize logistics across the entire plant or warehouse. Hikrobot’s software architecture is organized into a business layer, a management layer and an execution layer, connecting seamlessly with customers’ core systems such as WMS, MES and ERP.

RCS-2000 (Robot Control System)

RCS-2000 (Robot Control System) is the hub responsible for task allocation, scheduling, and operation and maintenance for all robots. It uses a variety of scheduling algorithms to achieve optimal task allocation, and through multi-robot path planning and traffic management it enables robots to cooperate efficiently without interfering with one another, maximizing operational efficiency. It also handles material transport between different scenarios, such as between a warehouse and a production line. RCS-2000 supports large-scale scheduling — thousands of AMRs, fields on the scale of millions of square meters, and up to 1,100 AMRs in a single project. It is built from modules such as TAS (task allocation), AMS (alarms), CMS (centralized management) and WCS (device management), and supports secondary development.

iWMS (intelligent warehouse management system)

iWMS-1000 is a business management system centred on inventory management, integrating a range of data-mining and AI technologies. It makes use of four low-code development components (iDataBus, iDataView, iDataClientView and iDataFlow) to enable flexible configuration and rapid response to custom requirements. Operations such as inbound, outbound, movement, stocktaking and inventory inquiry are optimized with business algorithms including storage recommendation, smart wave management, heat management and inventory allocation algorithms. By industry, iWMS-AUTO is available for automotive, iWMS-3C for 3C and iWMS-Logistics for the logistics industry, each adapted to the characteristics of its sector.

WCS and integration with core systems (WMS/MES/ERP)

The WCS (warehouse control system) handles integration with peripheral equipment such as conveyors, automatic doors, lifts and AS/RS. RCS, iWMS and WCS connect to the customer’s WMS, MES, ERP and OMS via international interface protocols, exchanging business data such as purchase orders, production orders, inbound and outbound movements, and sales orders in both directions. In actual cases, RCS-2000 has connected seamlessly with a customer’s WMS to deliver digital management of storage information, and iWMS has connected with a customer’s ERP to complete inbound and outbound operations. TOMAS TECH takes responsibility for everything from requirements definition for such core-system integration through to connection design and testing, delivering automation that leverages your existing information system assets.

As a guide to deployment scale, a standard FMR project typically consists of the FMR units themselves (as many as required) plus charging stations, manual controllers, navigation aids, PDAs and button boxes, together with software (iWMS-1000 × 1, RCS-2000 × 1, WCS × 1, Rose hot backup × 1), 2 servers, 1 UPS, 1 server cabinet and 1 WiFi network. The design assumes stable operation, including redundancy (primary/secondary server configuration, dual AC configuration and UPS).

Applicable industries — at work across diverse manufacturing and logistics sites

Thanks to their versatility, FMRs are being adopted across a wide range of industries. Among the manufacturers TOMAS TECH supports in Thailand and ASEAN, demand for deployment is growing particularly in the following sectors.

• Lithium batteries and new energy: a field with heavy pallet transport and storage, where both safety and storage density are required. The Reach-truck / Counterbalance Series and the Omnidirectional Series are active here.
• Beverages: characterised by high-frequency transport of heavy loads. High-rack put-away and retrieval and high-speed transport with the Reach-truck / Counterbalance Series are effective.
• Home appliances: a field handling a wide variety of pallets and totes. The Reach Series, which handles many pallet types, is a good fit.
• Automotive parts: a field running complex logistics at high frequency, including plant-wide transport of raw materials, finished goods and empty boxes, and tote put-away and retrieval via conveyor integration. Narrow-body designs solve the safety issues of mixed personnel.
• 3C (computers, communications and consumer electronics): a field requiring high-density storage and narrow-aisle operation. The Omnidirectional Series shows its strengths here.
• Tobacco and printing: a field requiring high-density storage and FIFO (first-in, first-out) management. Combining ground stacking and aisle-type storage with FMRs is effective.

In addition to these, any manufacturing or logistics site handling pallets or roll cages is a candidate for FMRs, including panels, semiconductors, smartphones, pharmaceuticals, apparel, and e-commerce and retail. TOMAS TECH will propose the optimum series, unit count and system configuration based on your industry characteristics and site conditions.

How to think about deployment examples — lessons from three representative cases

Here we generalise the elements of representative Hikrobot FMR deployments and introduce the kinds of results that can be expected. Please use them as a reference for applying the concepts to your own site and making the deployment picture more concrete.

Case 1: large-scale manufacturing plant (example of the Bosch Nanjing plant)

In this case, 21 FMRs were introduced to automate the entire process chain spanning the production plant, the raw material warehouse and the finished goods warehouse. Raw materials issued from the warehouse are delivered automatically to each production line, and finished goods are automatically put away into the warehouse. RCS-2000 connected seamlessly with the customer’s WMS, delivering digital management of storage information and smooth changeovers across the whole production line. In terms of results, automated AMR transport of raw materials and finished goods cut the response time for formulation by 15 minutes, “AMR + high-bay warehouse” cut more than 5,000 m² of storage area, and more than 60 workers were reduced across the whole plant. It is a fine example of end-to-end optimization of a complete logistics chain — raw material storage, quality inspection, packing, sorting, delivery and finished goods shipment.

Case 2: automotive parts plant

In this case, 43 FMRs were introduced to automate line transport of raw materials and finished goods for brake systems. Raw materials, finished goods and empty boxes are transported automatically across the whole plant, and automated put-away and retrieval of multi-size totes is achieved through integration with conveyor lines. Multi-system integration of RCS-WCS-ERP-AS/RS delivered intelligent management of warehousing and transport. The brake system plant has a working area of 12,000 m² and a production efficiency of 300 pallets/h, and transports a variety of carriers including wooden pallets and bins. Narrow-body forklifts solved the safety issues of a cramped site with mixed personnel and responded rapidly to high-frequency transport tasks, improving the efficiency and accuracy of transport as well as the level of production management.

Case 3: warehouse in the printing industry

In this case, 5 FMRs were introduced to automate inbound and outbound operations in the printing industry. iWMS was connected to the customer’s ERP to complete inbound and outbound work. Aisle-level picking via TPS achieved FIFO and made it possible to place different batches of the same SKU in the same aisle. The system integrates with a lifting conveyor line, with scan cameras installed on the conveyor for verification. The configuration uses floor-level ground stacking plus aisle-type storage, with back-to-back storage for some small-quantity orders. It completely eliminated the confusion and slowness on the floor caused by manual transport, replacing manned forklift work and delivering labor savings and a higher level of automated warehouse management. It is a fine example of clear results being achieved even from a small number of units.

Deployment process and timeline — from contract to live operation

FMR deployment proceeds in stages, from requirements confirmation through to live operation. For a standard FMR project, the overall picture from contract and PO through to go-live and ramp-up is as follows (the durations are guidelines only and vary with scale, customization and shipping destination).

1. Contract signing and PO: blueprint, finalisation of layout and design, project kick-off.
2. Detailed engineering (about 1 month): detailed design reflecting site conditions.
3. Standard manufacturing period (about 2 months): material preparation, manufacturing and external procurement. Allow an additional 2–4 weeks if there is extra customization.
4. Shipping (about 2 months): from the plant in China to the port, sea freight, customs clearance, and from the port to the customer site. The duration varies with the destination region.
5. Installation and implementation (about 1.5–2 months): hardware installation, AGV commissioning and system commissioning.
6. Live operation and ramp-up (about 1 month): start of operation and the ramp-up period.

TOMAS TECH’s system implementation process proceeds through the following steps: current-state analysis (interviews on operations and systems in use, requirements confirmation, and preparation of the quotation), requirements definition (confirmation of detailed requirements in line with actual operation), design (basic design, detailed design and migration preparation through process meetings), build and test (fit-to-business verification and testing, and consideration of the migration approach), implementation support (parallel running, operator training sessions and acceptance testing), and live operation (long-term support through operational maintenance support, a help desk and the provision of revised versions). Including the pre-sales phase, a typical guideline is a minimum of about 30 weeks and a maximum of about 42 weeks. Because we work in Japanese, Thai and English, local subsidiaries of Japanese companies can also run their projects with confidence.

Pre-deployment checks — site infrastructure items to confirm

For an FMR to operate reliably, site infrastructure conditions must meet certain standards. TOMAS TECH conducts a site survey before deployment and confirms the items below. Where the standards are not met, we propose advance countermeasures such as floor remediation or network reinforcement.

Floor conditions (flatness, gradient, steps and grooves)

• Floor undulation (flatness): the height difference between the highest and lowest points within 1 m² must be 2mm or less. The floor must be clean, free of particles and dirt, and not slippery.
• Surface gradient: over a length exceeding 100mm, the ratio of horizontal height difference to length must be 0.05 or less. At points requiring precise stopping positions, it must be 0.01 or less.
• Steps: the horizontal height difference within a length of 100mm must be 5mm or less. However, there must be no steps at stopping positions.
• Groove width: must be 8mm or less. There must be no grooves at stopping positions. Where the groove width is exceeded, the same requirements as for steps apply.

Environmental conditions (temperature and humidity, air quality, power supply, static electricity)

• Place of use: an indoor, level floor surface.
• Ambient temperature: 0°C to 45°C.
• Humidity: 15% to 95%, non-condensing.
• Air quality: free of dust and of flammable, explosive or corrosive gases.
• Power supply: 220V (±10%) AC, 50Hz (±2%).
• Static electricity: the flooring material must dissipate static electricity readily. In environments with electromagnetic waves, stray light, ultrasound or electrostatic noise, confirm in advance the effect on normal AGV operation.

Communications (WiFi) conditions

Wireless APs are deployed in the number necessary and sufficient, taking cost and mutual interference into account. Note the differences between omnidirectional and directional APs (coverage area and mounting method), and use non-overlapping channels (1, 6 and 11) for adjacent APs. APs are installed at a height of 3m, with a recommended tilt angle of 7–9 degrees for optimum coverage over a 15m radius. Signal attenuation caused by physical barriers such as walls must also be taken into account. Signal strength in the AGV activity area is required to be stronger than -65dBm, and the test criteria are a signal strength of -70dBm or better, a ping test with 1500-byte packets showing latency under 300ms, and uplink and downlink speeds of at least 4Mbit. A dual AC redundant configuration is recommended for a stable wireless environment.

Charging infrastructure

Each individual charging station requires a power circuit of at least 2000W (4000W for some models) at 220V AC. Every charging station must have a circuit breaker or fuse, and the main input must include an earth-leakage protection device. The ambient temperature around a charging station must be at least 0°C and no more than 50°C, with relative humidity of 90% or less and good ventilation. Automatic charging control based on remaining battery level (for example, stopping task acceptance and starting charging when the level falls below a lower threshold, and stopping charging when it exceeds an upper threshold) delivers operation that does not come to a halt.

Maintenance and support — the structure behind long-term stable operation

Deployment is not the end of the FMR story: keeping the system running reliably over the long term is the key to recovering the investment. TOMAS TECH supports your continued operation with the maintenance and support structure below.

• Operational support and recovery assistance: we open a support desk and provide operational support by telephone and email, together with recovery assistance in the event of software failure (standard service).
• Provision of upgraded software versions: when functional improvements are made, we provide the upgraded version. By supplying the latest software compatible with the latest OS, there is no need to purchase software again when servers are replaced, reducing lifecycle costs (standard service).
• Hardware maintenance: in the event of a server failure, we or the hardware manufacturer carry out on-site repair including parts replacement (optional; applies where the hardware was purchased from us).
• Software re-setup: where software needs to be set up again after a server failure has been repaired, we carry out the restoration work (standard service).

In the first contract year, services are provided within the scope of the system purchase fee; from the second year onwards the contract is renewed annually. Together with a redundant configuration (primary/secondary servers with Rose hot standby, dual AC and UPS), we propose an operational design that minimizes the risk of unplanned downtime. Operating data can be visualized in RCS-2000 and iDataView, allowing analysis of task execution rates, anomalies and route congestion to feed continuous improvement.

Frequently asked questions (FAQ)

Q1. We are not sure which series to choose. What are the selection criteria?

Start by clarifying four points: the maximum weight of the loads to be transported, the lift height required (number of rack levels), the transport speed you need, and your aisle widths and storage format. As a basic guideline: the Omnidirectional Series for narrow aisles and high density, the Stacking Series for stacking onto high racks, the Transport Series for high-speed horizontal transport, and the Reach-truck / Counterbalance Series for handling diverse pallets and general versatility. In practice a combination of several series is often the optimum answer, and TOMAS TECH will make a proposal following a site survey.

Q2. Can it integrate with our existing WMS or ERP?

Yes. RCS-2000, iWMS and WCS connect to the customer’s WMS, MES, ERP and OMS via international interface protocols. In actual cases, RCS has connected with a customer’s WMS to manage storage information digitally, and iWMS has connected with a customer’s ERP to complete inbound and outbound operations. TOMAS TECH handles everything from defining the integration requirements through to connection design and testing.

Q3. Can it operate safely in the same space as people?

FMRs feature a multi-layered safety design with 360° environmental perception, obstacle-avoidance lasers detecting up to 20m, fork-tip sensors, bumper strips and tri-color lights, and they decelerate, stop or take avoiding action when a person or obstacle is detected. However, there are detection limits for transparent or highly reflective objects and for extremely low or suspended objects, so we design to minimize blind spots using options and laser height adjustments suited to the site.

Q4. How long does deployment take?

For a standard FMR project, the guideline from contract to live operation is roughly 8 months (1 month of detailed design + 2 months of manufacturing + 2 months of shipping + 1.5–2 months of installation + 1 month of ramp-up). If there is customization, allow an additional 2–4 weeks. For the system implementation as a whole, including the pre-sales phase, a minimum of about 30 weeks and a maximum of about 42 weeks is typical.

Q5. Are there benefits even with a small number of units?

Yes. In the printing industry case, 5 FMRs automated inbound and outbound operations and eliminated the confusion and slowness caused by manual transport. It is also possible to start small, confirm the results and expand in stages. RCS-2000 supports up to 1,100 units in a single project, so it scales to future expansion as well.

Q6. Are there conditions such as flooring or communications that we need to prepare on site?

Yes. Requirements include floor flatness (undulation of 2mm or less within 1 m²), gradient (0.05 or less, and 0.01 or less at precise stopping points), steps (5mm or less), groove width (8mm or less), ambient temperature of 0–45°C, humidity of 15–95% non-condensing, a 220V power supply, and wireless signal strength of at least -65dBm in the AGV activity area. We confirm these in a site survey before deployment and propose advance countermeasures where anything falls short.

Q7. How should we choose between an FMR and other types such as low-profile LMRs?

The FMR can pick up pallets directly from the ground, handles racks of various heights, and offers high-speed transport and high storage density as its strengths, but it assumes racks or elevated platforms and open-entry pallets. Low-profile and rack-transport types (LMR), on the other hand, are strong at avoiding suspended objects and at high-density storage with single- or multi-level racks. On the shop floor, collaborative operation — FMRs in the main aisles and LMRs for the finer work — is also effective. TOMAS TECH will design the optimum combination according to your requirements.

Summary — find the best answer for pallet transport automation with TOMAS TECH

The forklift AGV/AMR (FMR) fundamentally resolves the safety, workforce, operational and cost challenges of manned forklifts, and is a practical means of making pallet transport unmanned and standardized. It covers a broad range — rated load of 300–3000kg, lift height up to 4.5m and speed up to 2m/s — with four series (omnidirectional, stacking, transport, and reach-truck / counterbalance) plus extensive customization, and it achieves safe autonomous travel alongside people through 360° perception and SLAM navigation. Furthermore, by integrating with your existing WMS, MES and ERP via RCS-2000, iWMS and WCS, it goes beyond merely automating transport to optimize logistics across the entire plant or warehouse.

The key to success lies in correctly assessing your own transport requirements, storage formats and infrastructure conditions, and then drawing up the optimum series, unit count, system configuration and deployment plan. As an IT integrator specializing in the manufacturing and logistics industries in Thailand, TOMAS TECH provides consistent, end-to-end support for Hikrobot FMRs — site survey, selection, host-system integration, installation, commissioning and maintenance — in Japanese, Thai and English. From an initial inquiry along the lines of “where should we even start?” through partial deployment on an existing line to large-scale, full-process automation, we promise realiztic proposals grounded in the realities of your site. If you are considering automating pallet transport, please do get in touch.

Please send your inquiry via our contact form. Tell us about the challenges and requirements at your site, and we will propose the FMR deployment plan best suited to your company.