The Client  

A global manufacturer that specializes in energy management and automation, providing solutions for homes, buildings, data centers, infrastructure, and industries to optimize energy use and improve efficiency. Their focus is on helping customers make the most of energy and resources, bridging progress and sustainability through electrification, automation, and digitization.  

The Challenge 

The client was experiencing operational challenges due to persistent labor shortages, workforce turnover, and absenteeism at three of its manufacturing facilities located in El Paso, Texas. These constraints were impacting material handling efficiency and placing added strain on plant operations. The organization engaged BlueSkye Automation to provide a solution to help mitigate these workforce limitations while enhancing throughput, reducing travel time, and supporting its broader Industry 4.0 objectives.

The Solution  

BlueSkye Automation deployed Geek+ MP1000R AMRs to automate internal material transport workflows within the three El Paso facilities. These autonomous mobile robots (AMRs) were integrated into several mission-critical applications, including:  

  • Transport of finished goods pallets from staging and warehouse areas to shipping zones. 
  • Removal of corrugated waste containers from production lines to recycling stations, with return of empty containers. 
  • Movement of scrap bins from line-side to designated scrap collection areas, including automated return of empty bins. 

As the systems integrator, BlueSkye delivered a turnkey solution following a structured, collaborative implementation approach, including the following components:  

  • Solution scoping and design, including Facility and IT infrastructure readiness. 
  • On-site commissioning and deployment of Geek+ MP1000R AMRs equipped with automated opportunity charging functionality. 
  • Integration of Geek+ fleet management software for seamless coordination and monitoring of AMR workflows. 
  • Implementation of advanced safety features, including pallet detection sensors, custom blue safety lighting, and a comprehensive hazard risk assessment. 
  • Provision of supporting infrastructure such as pallet transfer conveyors, pickup-and-drop-off (P&D) stands, custom material racks, server hardware/software, and wireless control interfaces. 
  • Go-live execution support, delivery of operator training programs and extensive workflow testing and optimization. 
  • Provided a structured aftermarket service and preventative maintenance plan to ensure long-term system reliability. 
The Impact  

The deployment of AMRs delivered measurable improvements across the client’s operations, reducing material transport time and eliminating over two hours of manual walking per operator per day (~250 feet per one-way trip).  

  • A substantial decrease in reliance on Powered Industrial Truck (PIT) traffic in pedestrian zones, thereby enhancing plant safety through predictable AMR navigation and advanced collision avoidance systems.  
  • Increased throughput and improved order fulfillment rates. 
  • Support for Industry 4.0 initiatives, enabling more agile, connected, and scalable operations. 
  • Minimal disruption to existing workflows, with successful integration into highly dynamic manufacturing environments. 
Client Feedback 

“I joined this project during the execution phase and was impressed by the professionalism and responsiveness of the BlueSkye Automation team. Despite several unforeseen network challenges, the BlueSkye team remained solution-focused, collaborative, and highly supportive throughout the process. The project was executed successfully, and I look forward to future opportunities to work with this team.” 

-Manufacturing Engineer

Conclusion 

Through the successful implementation of autonomous mobile robots, the client has enhanced its material handling capabilities, reduced operational dependencies on manual labor, and taken a significant step toward achieving its smart factory goals. BlueSkye Automation’s technical expertise, flexible project execution, and customer-centric approach were critical to the initiative’s success. 

How can BlueSkey Automate Your Warehouse? 

BlueSkye Automation is poised to help companies sustain highly efficient and productive operations by integrated advanced robotics.

To learn more about what we can do for your business, contact us today.