Rethinking production logistics — forklift-free, safe, space-saving

Standing in the way was yesterday: With the automated shuttle solution from advasolutions, you can move raw materials, semi-finished products and components to new levels — free from bottlenecks, cruises and manual handling. In this way, you reduce the use of personnel, the risk of injuries and possible sources of error and at the same time gain valuable space for safe, smooth production and efficient logistics in your company.

Forklift free

Safe

Space-saving

Production logistics under pressure — when routes are blocked, processes come to a standstill and there is a shortage of skilled workers

In production logistics, every second counts — materials must be available just-in-sequence. But rigid conveyor technology, narrow traffic routes and staff shortages jeopardize a smooth flow of materials and increase the risk of accidents. Especially in clock-critical processes, the slightest disruptions lead to downtimes, claims for recourse and expensive additional costs. The desire for a forklift-free, flexible factory is therefore not just a vision of the future, but an operational necessity.

Typical challenges in production logistics:

Disturbances in material flow:

Delayed or incorrectly provided materials lead to production stops, expensive downtimes and claims for redress from end customers.

Shortage of personnel:

There is a lack of skilled workers — manual transport with forklifts, for example, is becoming a cost and reliability trap.

Loss of valuable space:

Traffic routes block space that could be used for machines, buffers or warehouse processes.

Shortages on traffic routes:

Forklifts, AGVs and people share the same routes — leading to traffic jams, chaos and increased accident risks.

Lack of layout flexibility:

Machine conversions require adjustments to the conveyor technology — which costs time and money.

No integrated buffer solutions:

Intermediate storage facilities for semi-finished products, empties or WIP can hardly be integrated to save space.

Intelligent warehouse automation — our answer to your challenges

Intelligent intralogistics instead of bottlenecks — the forklift-free alternative for modern production

In traditional factories, material flow occurs on the ground, both in storage and production areas – precisely where people work, machines operate, and every square meter counts. This leads to bottlenecks, collisions, and rigid layouts.

advasolutions' automated shuttle solution therefore reimagines production logistics. It shifts material flow to previously unused areas of the facility – above machines, along the ceiling, or through narrow gaps. This transforms the system into an invisible background infrastructure: safe, space-saving, and forklift-free.

The forklift-free future: Rethinking material flow

The core of the advasolutions solution are autonomous AdvasHuttles (driverless vehicles), which move horizontally, vertically and laterally through the warehouse and production environment. This is made possible by a variable shelving system — the AdvaRacks — with integrated rails, which does not require central lifts or complex conveyor technology. This creates new, independent transport routes across existing systems, through narrow ceiling spaces or between halls.

In addition, ADVAShelfs serve as sturdy storage shelves for a wide variety of goods — from open components to boxes, trays or containers, without any additional packaging. With the advasolutions system, products up to 800x400x600 mm and 25 kg can be stored and transported.

Digital control for maximum transparency in logistics

All goods movements are controlled by the self-developed Warehouse Execution System (WES). It acts as a digital twin of your logistics: As soon as the goods are received, AdvaInbound can automatically record all item data for seamless traceability from the first process step — via 3D scan including photo, weight, dimensions, barcode and MHD/batch information.

The WES plans transports, allocates storage spaces, tracks all movements in real time and ensures that the right material is in the right place at the right time with the help of driverless vehicles. The AI-based software can be seamlessly integrated into existing WMS and ERP systems.

Optimum material flow thanks to forklift-free logistics

Whether it's production supply, sequence-specific delivery to the assembly site, transportation of semi-finished products between production steps or collection of empties and finished parts — the logistics system automates all supply processes during operation. Buffer warehouses (WIP) can also be seamlessly integrated, which enables flexible intralogistics.

External service providers can be connected without entering sensitive areas — for greater security and less coordination effort. The combination of driverless vehicles and digital control reduces risks, saves space and accelerates the entire material flow.

The business advantage, your benefit. Your benefits with automated production logistics

More safety, less downtime: With the shuttle-based solution from advasolutions, you can transform material flow from a mandatory task into an invisible, intelligent infrastructure. Secure, scalable, stack-free.

No traffic risk
on main routes:

Material is transported over separate levels — without collisions with people or forklifts. This reduces the risk of accidents and relieves your employees.

Flexible machine connection
without conversion:

Production machines can be rearranged at any time. The system adapts without fixed conveyor technology or complex modifications.

Integrated buffer zones:

Materials, semi-finished products and empties are automatically stored and provided just-in-sequence — for > 98% supply security in time-critical logistics processes.

Can be used across halls:

Whether raw material from incoming goods or components from upstream logistics areas — all stations can be connected securely and using data.

Repatriation of empty containers
and finished products:

The entire material cycle — from raw material to return transport — runs automatically using the same system.

Modular expansion in
all directions:

The system grows with you — even on floors or across hall boundaries. Ideal for changing production requirements or space shortages.

Intelligent control
for maximum efficiency:

AI-based route planning optimizes the utilization of driverless vehicles (shuttles) in order to avoid traffic jams and carry out every movement efficiently.

Our Application Areas – as versatile as your production

Whether automotive, pharmaceutical, or food: The advasolutions shuttle system flexibly adapts to various production and logistics environments.

Automotive – efficient & just-in-sequence production: advasolutions enables just-in-sequence supply for assembly lines – without manual intervention, bottlenecks, or traffic risks.

Mechanical Engineering – flexible material flow despite changing layouts: Machines, workshops, and production islands can be rearranged at any time – the driverless shuttle system adapts without requiring modifications.

Chemical Industry – safe & controlled conveyance: Materials and intermediate products are moved automatically, without human contact and without cross-traffic through sensitive areas.

Electronics Industry – fully traceable & error-free: The smallest components and parts are uniquely identified, scanned, and transported – ESD-tested for maximum process reliability.

Food Industry / Pet Food – hygienic & continuously supplied: Automated transport replaces forklifts, prevents contamination, keeps paths clear, and secures production – even for sensitive products.

Pharmaceutical Industry – strictly documented & with no external access: Thanks to digital control and automated handover, sensitive products remain controlled, traceable, and tamper-proof.

Your path to forkliftless production logistics

Our proven implementation process, from data-based analysis to ongoing operation, reliably guides you to automate your production company:

1. Analysis & concept

✔ Together, we analyze material flows, production processes, and spatial structures. Based on this, we develop a flexible, forklift-free automation concept for your intralogistics.

2. Implementation & integration

✔ Planning and installation of components. Seamless physical and digital integration into your existing operations. Thanks to Plug & Play, this is achieved without extensive modifications.

3. Operate & Scale

✔ Go-Live, followed by training, support offerings, and system enhancements for stable and efficient operation. Today and in the future.