How the MHP Fleet Executer is Revolutionising Intralogistics at Porsche

Innovation with Vision: A Control System for All  Autonomous Transport Systems

Modern vehicles are equipped with an increasing number of features, technical systems, and components. In automotive production, this leads to a high volume of different material transports. To manage this growing complexity, innovative solutions for in-plant logistics are essential. Automated Guided Vehicles (AGVs), as part of Autonomous Transport Systems (ATS), play a key role in this process. These automated transport vehicles ensure efficient, reliable, and flexible material supply. 

Porsche, the renowned sports car manufacturer, also sought to further automate its production-related intralogistics. However, it lacked a central control concept to coordinate the various Autonomous Transport Vehicles (ATVs). In particular, Porsche AG was faced with the following challenges:  

• No comprehensive, manufacturer-independent fleet management: Porsche AG's existing and newly introduced AGVs have to navigate lifts, gates and systems from different manufacturers and generations within the factory. In addition, the plants operate a wide range of AGVs that must work together seamlessly. To achieve this, an innovative fleet management system was needed, capable of coordinating AGVs from different manufacturers. 
• A new automation control architecture needed: To implement a centralized control system and the associated standardization, Porsche required a cross-manufacturer, easily scalable, and highly adaptable IT infrastructure. The fleet management solution also needed to be integrated with the Digital Production Platform (DPP), which is based on the AWS cloud hyperscaler 
• Ensuring operational reliability: Reliable processes are essential in Porsche's automotive production. The fleet management system must maintain ATS operations even in the event of partial system failures.

The FleetExecuter and AWS DPP: A Future-Proof Combination for Intralogistics

To meet these challenges, Porsche AG chose the MHP FleetExecuter, a cloud-based, manufacturer-independent control software for Autonomous Transport Vehicles. Supporting the VDA 5050 communication standard, FleetExecuter enables the seamless integration of Autonomous Transport Vehicles and robots via this interface, even across different manufacturers. This flexibility was a key factor for Porsche. Developed further within the AWS Digital Production Platform (DPP) cloud, the solution was first fully modeled and simulated digitally before being tested physically at MHPLab in Ludwigsburg and within a customised cloud infrastructure. The software was ready for use just a few months after the start of the project. The project involved four stakeholders and 100 participants, with numerous system integrations across proprietary and third-party platforms. More than 150 features were developed to enhance the solution.

How is the FleetExecuter structured?

The solution developed for Porsche is built on a state-of-the-art, cloud-ready architecture designed for maximum flexibility and scalability. Its core components include: 

• A modular architecture 

• Advanced route optimisation algorithms 

• Real-time monitoring and proactive error management 

• An intuitive user interface 

• Extensive interfaces for seamless integration with existing systems

FleetExecuter features overview

Building on its core elements, FleetExecuter offers a wide range of valuable features for autonomous transport systems:

• Intelligent task optimization:

  • Automatic calculation of optimal routes 

  • Dynamic adjustments in case of disruptions 

  • Maximized fleet utilization  

• Multi-vendor integration: 

  • Centralized control of different ATS types 

  • Standardized interfaces 

  • Seamless integration with existing systems

• Comprehensive safety concept:  

  • Redundant systems 

  • Automatic emergency procedures 

  • Proactive fault detection

• Intuitive operation: 

  • Clear visualization 

  • Real-time monitoring 

  • Detailed analysis functions 

Results That Speak for Themselves: The Impact of FleetExecuter

The FleetExecuter not only delivers a significant increase in efficiency, but is also highly reliable. In practice, companies benefit from: 

Greater efficiency through intelligent automation

With its modern and flexible architecture, the FleetExecuter optimizes large parts of in-plant logistics:

• Up to 20% increase in overall efficiency: Implementing the FleetExecuter can boost overall intralogistics efficiency by up to 20%. Its intelligent algorithms optimize vehicle utilization and significantly reduce waiting times. Where manual coordination and rigid schedules once dominated, dynamic real-time optimization now ensures much higher throughput while reducing resource consumption. 

• Optimized transport routes and fewer empty runs: Advanced routing algorithms continuously calculate the most efficient paths for each vehicle based on real-time demand and system status. The system automatically identifies opportunities to combine tasks, significantly reducing empty runs. In practice, this results in better vehicle utilisation, lower energy consumption and reduced system stress. 

• Improved material supply to production: FleetExecuter increases the reliability and accuracy of material supply. It anticipates demand, responds to production changes in real time and ensures materials arrive exactly when and where they are needed. By working seamlessly with production processes, it minimises waiting times and virtually eliminates disruptions caused by material shortages.

Maximum uptime through proactive management 

Tailored to the needs of the manufacturing industry, the FleetExecuter delivers high reliability and intelligent contingency planning. 

• 99% system availability: FleetExecuter achieves up to 99% system availability through redundant system architecture and intelligent load management. Even in the event of partial failures or maintenance work, the system remains operational, ensuring continuous material supply. This is particularly crucial for just-in-time production in the automotive industry. 

• Automatic fault detection and correction: FleetExecuter continuously monitors all system components to detect potential problems before they impact operations. Machine learning and predictive analytics are used to identify anomalies early and trigger automatic countermeasures. If a vehicle is overloaded, transport tasks can be redistributed, and in the event of technical problems, alternative routes and resources are activated. 

• Intelligent emergency management: Integrated emergency procedures ensure stable operations even in exceptional situations. If an elevator malfunctions or transport routes are blocked, FleetExecuter automatically initiates predefined alternative scenarios. The system reprioritizes critical transports, recalculates routes, and dynamically adjusts resource allocation. This adaptability ensures a steady supply of materials, preventing production disruptions even under the most challenging conditions. 

What Makes This Project a True Success Story

Since June 2023, the MHP FleetExecuter has been managing 1,600 material transports, including loading trips, carried out by 27 Automated Guided Vehicles (AGVs) over a 750-meter route at Porsche’s central Zuffenhausen site, specifically in Plants 2 and 3. The Software-as-a-Service solution coordinates elevators, high-speed doors, and existing infrastructure, ensuring seamless navigation. On their route between various high-bay storage areas, the AGVs pass through four automatic doors, a double lift system and four intersecting external systems. Further projects are already in the pipeline, including integration into "Building 70", the Porsche Taycan assembly hall, where new AGVs will further enhance production logistics. 

A Gamechanger for Porsche's In-Plant Logistics

The FleetExecuter has enabled Porsche to modernize its intralogistics in record time, preparing it for future challenges. Marc Lösken, Head of Porsche Brand Logistics, comments: "I'm pleasantly surprised that the project has been so successful, even with a short implementation period of only nine months." 

The implementation of the FleetExecuter at Porsche vividly demonstrates how innovative technological solutions can revolutionize intralogistics. With its modular architecture within the AWS DPP Cloud, extensive features, and proven practicality, the FleetExecuter sets new standards in intralogistics. It provides the basis for efficient, flexible and future-proof material supply in modern production and logistics. 

Are you also looking for an innovative solution for your intralogistics? With FleetExecuter, MHP helps companies optimize their logistics processes and make them future-ready. Let’s take your intralogistics to the next level together: MHP is here to support you as a trusted and reliable partner.

More infos about the MHP Fleet Executer