Precision shuttle system drives efficiency for EV spares

Faced with growing spare parts complexity and limited warehouse space at their Hosur factory, an electric two-wheeler manufacturer required a smart storage solution for better efficiency and smoother operations.

Case summary : We designed and implemented a 21-metre-high Shuttle Automated Storage and Retrieval System (ASRS), providing 1,100 pallet positions with customised beam arms and shuttle sensing technology. Our solution featured GTPS with positional slots for precise shuttle sensing, span deflection controlled within 5mm, and chamfered guides for smooth shuttle movement. Our system maximised vertical space while ensuring seamless integration with conveyors and fire safety systems. Our solution supported the client’s growing demand for agile, eco-friendly transportation, combining advanced automation, precision, and ergonomic design. We completed all upgrades without disrupting warehouse operations.

About the client : For a fast-growing EV maker, efficient warehouse management fuels growth

The client is a leading electric two-wheeler manufacturer that speacialises in urban scooters. Driven by rapid growth from increased demand for eco-friendly transportation and a direct-to-consumer model, they required precise spare parts management and streamlined warehousing to maintain efficiency and support expansion.