Power Equipment·Xi’an, China
Challenge
Cummins, a global power equipment manufacturer founded in 1919, needed to transform its Xi’an engine plant — its only production base outside North America — into a smart logistics factory.
Key challenges included:
- Logistics scope spanning the full material flow: raw material inbound, transfer, repackaging, warehousing, picking, line-side delivery, finished goods transfer, empty container return, and scrap collection.
- Mixed material profiles — small parts and large engine components coexisting on the same site.
- A long-term goal of a unmanned factory, which had to be built in phases alongside live production.
- Conventional manual operations could not support the planned scale and throughput.
Solution
ENGOAL delivered an integrated smart logistics solution for the Cummins Xi’an “Phoenix” project, including:
→ WMS-WCS system — conveying system → Large-unit automated warehouse + small-unit automated warehouse with top-in / bottom-out → SPS-AGV delivery → Robot-based fast storage system for sequencing outbound → Large-component sequencing
Two technology innovations were introduced:
- A combined top-in/bottom-out small-part storage + SPS picking model.
- The use of an automatic robot fast-storage system for sequencing outbound — a first-of-its-kind application.
- The design also put strong emphasis on ergonomics for operators on site.
The first phase has been completed and put into operation.
Results
- Full material flow — from raw material inbound to finished goods and empty-container/scrap handling — integrated on one platform.
- Two patented-style operational models proven in production: SPS + top-in/bottom-out picking, and robot fast-storage for sequencing.
- Phased delivery approach allowed live production to continue throughout the build-out.
- Ergonomic working conditions built into the system from day one.
Industry Value
The Cummins Xi’an project sets a phased blueprint for heavy-duty powertrain and automotive component manufacturers pursuing the “unmanned factory” vision — combining small-part automation, large-component automation, AGV delivery, and robot-based sequencing without requiring a full greenfield rebuild.
