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Each day, dozens of FedEx, Deutsche Post and United Parcel Service delivery trucks pull up to the loading docks behind Bldg. 2127 on Ramstein to deliver items from chemical gear to automotive parts.
Every month, more than 1,200 line items worth $20 million process through the 86th Logistics Readiness Squadron warehouse doors.
Since 2001, the majority of these parcels were loaded onto a conveyor belt system, a series of powered tracks that move the boxes from one end to the other, in the 120,000 square foot building.
Today, that conveyor system has been replaced by the Air Force’s first of its kind laser Automated Guided Vehicle System, said Larry Head, Air Force Materials Handling Engineering Flight industrial engineer.
Five E&K Automation robotic vehicles are now patrolling up and down the warehouse stopping at designated points, picking up parcels and moving them to designated locations more than a quarter mile away before dropping them off and moving to the next location.
“The key to this system is flexibility,” Mr. Head said. “Because it is laser guided, we can change the vehicles’ paths or add other vehicles at a later date if mission increases require it.”
Although the new system still costs $5,000 annually to maintain the AGVs, it drastically reduces the cost of maintaining the 9-year-old conveyors from $40,000 each year.
“In addition to saving the Air Force money, the new vehicles are a quality of life improvement,” said 2nd Lt. Amanda Callister, 86th LRS materiel flight manager.
“The old conveyor system was very loud,” said Eduard Junko, 86th LRS chief of operations who has worked in and around Bldg. 2127 for more than 15 years.
Achieving such Air Force Smart Operations for the 21st Century goals like reducing maintenance cost and noise while increasing efficiency, the new AGVs have also freed existing manpower to help in other areas throughout the warehouse.
“Now, technicians who had to move items from a drop location to the conveyors or drive forklifts can be freed up to pull parts or process shipping documents,” Mr. Junko said.
Each of the five laser guided vehicles are capable of working 30 hours on a full charge, and on low battery the vehicle returns to charging locations at the end of the warehouse.
Although still using forklifts for some loads, the AGVs have already made an impact in the facility, and there are other capabilities that have not been explored yet.
“I have been designing these systems for 25 years, but this is the first time I have recommended this AGV system for a unit,” Mr. Head said. “Although the warehouse is old, it is large enough that we can fully explore the capabilities of the laser guided vehicle. It simply works perfectly.”
