Automated Robot Operations Solution

The Challenge

More and more factories are investing in autonomous mobile robots (AMR/AGV) to move goods, replace forklifts, and cut reliance on manual labor. But as the robot count grows from a handful to dozens, a new problem appears: nobody knows where each robot is, what it’s doing, or when it needs to recharge. A few standalone robots can be tracked by eye, but once dozens of AGVs operate across thousands of square meters, manual oversight becomes impossible — leading to manual re-routing, path collisions, and unpredictable downtime.

The problem is more complex still for companies operating devices on behalf of multiple clients: they need one platform that can monitor hundreds of devices across sites simultaneously, with real-time data and the flexibility to scale as their client base grows. On top of that sits an integration challenge — robots need to connect to a facility’s warehouse management system, control system, or existing ERP, while most off-the-shelf robot solutions are optimized only for standalone operation. According to industry reports, over 45% of manufacturers in Vietnam have adopted automation to cope with labor costs and shortages, yet only about 12% of factory workers are proficient with automated equipment tools — showing that hardware investment is only half the picture.

The Solution

KAITECH delivers automated robot operations solutions through an engineering team specialized in robotics and industrial IoT, working under a full-lifecycle service model: Business Analysis to correctly understand the client’s operational problem, Design & Develop for the coordination system itself, rigorous QA & Testing before real-world deployment, and ongoing Maintain & Support after go-live. On this foundation, KAITECH builds two complementary layers of solution:

Fleet Management System (FMS) — central coordination for an entire fleet of autonomous mobile robots (AMR/AGV) within one facility. KAITECH builds this software layer on integration and custom-development capability over ROS/ROS2 (Robot Operating System) — the industry-standard robotics framework — connecting each robot’s sensor data, control algorithms, and actuators into one synchronized operating system. The FMS tracks each robot’s location, status, trajectory, and task in real time; automatically detects low-battery robots and dispatches them to charging stations; and handles scheduling, traffic control, and route optimization to avoid congestion.

Remote Monitoring and Management (RMM) — designed by KAITECH for companies operating devices at a larger scale, supporting simultaneous monitoring of up to 500 devices. Beyond the mobile-robot coordination layer, KAITECH also develops complementary automation modules such as PLC (Programmable Logic Controller) control software and HMI (Human-Machine Interface) screens for operating machinery, along with device-to-cloud connectivity to calculate OEE (Overall Equipment Effectiveness) — extending visibility beyond the robot fleet to overall line productivity.

Key Features

• ✓Fleet-wide real-time monitoring: status, position, trajectory, and current task for every robot, updated continuously on one central dashboard.
• ✓Automatic low-battery detection and charge dispatch: eliminates manual tracking and prevents robots from stalling mid-shift.
• ✓Scheduling and route optimization: manual or automatic scheduling, with traffic control across multiple robots to prevent collisions.
• ✓PLC integration & HMI interfaces: PLC control software and intuitive HMI screens for operating robots and machinery, connected directly to field sensor data.
• ✓Integration with the existing ecosystem: connects to warehouse management, control systems, and ERP over wireless links, letting robots operate seamlessly within existing workflows.
• ✓Substantial scalability: from a fleet of a few dozen robots to a platform monitoring 500 devices simultaneously.
• ✓Flexible deployment: private or cloud infrastructure, matched to each company’s security requirements and budget.

Results in Practice

For a manufacturer with multiple production centers, KAITECH deployed an FMS to manage 20 AGVs operating across roughly 1,500 m², with a requirement for duplex long-range wireless communication between robots and the server. The system provides real-time status and map visibility across the entire fleet, fully resolving the “we don’t know where our robots are” problem.

At a larger scale, a company providing device-operation services needed a software platform to monitor devices for its future clients, with a requirement to support up to 500 simultaneously connected devices. The RMM platform built by KAITECH fully met the requirement, while also letting the client choose private, local, or cloud-based infrastructure depending on its business strategy.

When properly coordinated by an FMS/RMM software layer, robot investment pays off clearly: companies that adopt automation well report roughly a 25% productivity improvement and a 15% reduction in downtime, according to industry reporting. Every solution is developed by KAITECH to international industrial standards (ISA95, IEC 62443, ISO/IEC 15288, ISO 20140), with an engineering team experienced in robotics and industrial IoT — ensuring not just stable operation but also the safety and integration capability real production environments require.

Technology Foundation

The solution is built by KAITECH on ROS/ROS2 for robot development, long-range LoRa wireless connectivity for industrial environments, a FastAPI backend, a React front end, MySQL and MongoDB databases, InfluxDB and Grafana for real-time data visualization, and C/C++/C# control programming for hardware.