Project Overview

This project was delivered for an automotive supplier running an injection molding production environment. The goal was to replace manual forklift transports with automated guided vehicles (AGVs). The AGV setup was especially complex because the site had two floors, and AGVs had to move materials reliably between both levels.

We implemented the solution on the D4S platform, providing digital interfaces for shopfloor workers to trigger AGV transports based on SAP production orders and production steps. The AGV system was integrated into the platform in the same way as the injection molding machines and other shopfloor equipment, enabling a unified view of production and logistics.

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Business Value

The solution enabled a controlled, SAP-aligned material flow using AGVs, improving efficiency and reducing manual coordination in an injection molding operation.

Key outcomes:

• Reduced dependency on manual forklift transports

• SAP-driven, process-consistent material movements across production steps

• Faster and more reliable material supply between stations and floors

• Clear digital triggers for material requests and handovers

• Improved process transparency and fewer coordination errors

• Secure on-premises operation aligned with industrial requirements

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What We Built / Solution

Worker-Facing Digital Interfaces

• Digital actions for workers to:

  • request new materials

  • confirm that a production step was completed

  • trigger the next material move to the following station

SAP Process Alignment

• Transport triggers based on SAP production orders and step-level production logic

• Consistent traceability of material movements aligned with production execution

AGV & Machine Integration

• Integration of the AGV system into the platform

• Integration of injection molding machines using the same platform approach, enabling unified shopfloor orchestration

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Architecture Highlights

• Built on the D4S platform using a modular, integration-friendly architecture

• Deployed on-premises in the customer environment using Docker

• Designed to support a multi-floor AGV routing scenario and shopfloor-triggered workflows

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My Role

In this project I worked as:

• Project Lead

• Quality Assurance / Delivery Quality Owner

I ensured delivery quality through structured code reviews, supported the team on complex technical challenges, and stepped in for critical implementation tasks when needed.

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Technologies

• C# / .NET (ASP.NET Core)

• Java

• SQL Server

• Angular

• React

• SAP integration

• D4S integration interfaces

• Microservices architecture

• Event-driven architecture (messaging / asynchronous integration)

• Machine / IoT integration (injection molding machines)

• User management / Identity & access control

• Workflow-enabled UI modules

• AGV integration

• Docker (on-premises deployment)