BORG Automotive automates KLT logistics with MiR250

At BORG Automotive, thousands of components move between the warehouse and production every day. As production volumes grew, keeping that flow predictable became a business-critical task. The company needed more than faster transport. It needed visibility, traceability, and a way to make internal logistics easier to scale. 

BORG Automotive worked with Octant to automate the transport of KLT containers between its warehouse and production areas using three MiR250 autonomous mobile robots. The system connects BORG’s MES system with MiR Fleet and Octant Supervisor, so transport missions can be created, optimized, assigned, and confirmed automatically. 

“Every day, we work with a very large number of components. To keep production running smoothly, everything has to arrive at the right place at the right time. As our operations continue to grow, what happens between the warehouse and the production lines is just as important as production itself.” 

Grzegorz Olsztyn, Plant Director, BORG Automotive

Before automation, Borg Automotive used a manual milk-run process to move components from the warehouse to production. Operators collected parts and delivered them to multiple production areas using different transport containers. The process supported daily operations, but it became harder to maintain visibility and consistency as production demands grew.

The challenge was not only moving containers from A to B. Borg Automotive also needed confirmation that every KLT container reached the right destination, and that inventory movements between warehouse and production were recorded automatically.

“Our process is quite demanding. We work with a large number of different components, and the list is constantly changing. At the same time, we have many delivery points across production, and we need complete visibility of when a component has been delivered and exactly where it is.”

Michał Owczarek, AMR Project Manager, Group Supply Chain, Borg Automotive

Borg Automotive implemented a complete intralogistics solution tailored to its production environment. Octant designed the transport process around Borg’s workflows, including custom transport modules, warehouse infrastructure, software integration, and fleet management.

The final solution includes three MiR250 autonomous mobile robots, Octant Supervisor, MiR Fleet, dedicated transport modules for KLT containers, and integration with Borg’s MES system.

“In this project, it wasn’t just about deploying three MiR250 robots. Our task was to design a complete intralogistics system tailored to the way Borg Automotive operates.”

Yacine Senhadri, CEO/CTO, Octant

The MiR250 was selected because its compact footprint allows it to operate efficiently in Borg Automotive’s production environment, including narrow factory aisles. Each robot carries a custom transport module that can move up to six KLT containers in one mission.

How the automated flow works

The process starts in Borg’s MES system. A production operator places an order, and the warehouse prepares the required KLT containers based on the generated picking list. Once the containers are scanned and placed on the loading rack, the automated transport process begins.

Octant Supervisor determines where each KLT container should be loaded, assigns transport tasks through MiR Fleet, optimizes delivery sequences across production sectors, and confirms completed deliveries back to the MES system.

This gives Borg Automotive an automated flow that connects warehouse operations, production planning, and mobile robot transport in one coordinated process.

“Our goal was never simply to deploy robots. We wanted to optimize the entire process of transporting components between the warehouse and production. We were looking for a solution that would give us better control over material flow, provide feedback on completed deliveries, and integrate with our MES system.”

Michał Owczarek, AMR Project Manager, Group Supply Chain, Borg Automotive

Built around Borg Automotive’s production process

Octant developed a dedicated transport module for each MiR250. The dual-level roller system allows each robot to transport up to six KLT containers per mission, deliver components to multiple production locations in an optimized sequence, collect empty containers, and return them to the warehouse.

The system also includes warehouse racks, production racks, sensors, LED guidance, and IoT communication devices. Together, these elements support reliable and traceable material flow throughout the facility.

A phased implementation to reduce operational risk

Borg Automotive and Octant began with a detailed analysis of the existing logistics process, followed by workshops, process optimization, and visits to reference installations. Together, they designed a solution covering warehouse picking, transport, delivery confirmation, and the return of empty KLT containers.

To reduce disruption, the robots were first introduced in one production area. That gave the team a controlled setting to validate the process, refine hardware and software, and optimize robot traffic before expanding the system across the facility.

“One of the biggest challenges was optimizing the entire process, both from the software and hardware perspective. We had to ensure seamless MES integration, efficient task queuing, robot traffic management in narrow spaces, and route optimization between production sectors.”

Yacine Senhadri, CEO/CTO, Octant

Simple for operators, intelligent behind the scenes

Although several technologies work together in the background, the daily workflow remains straightforward for warehouse operators. They continue preparing production orders through the standard picking process. LED indicators guide container placement, sensors verify loading, and transport missions are generated automatically once the predefined conditions are met.

Instead of manually coordinating deliveries, operators prepare the materials while the software manages robot assignment, delivery order, and transport confirmation.

Today, the transport of production components between Borg Automotive’s warehouse and manufacturing areas runs automatically. Production operators place orders through the MES system, warehouse teams prepare the required KLT containers, and the autonomous mobile robots handle transport, delivery, and the return of empty containers.

The result is a more predictable material flow, fewer manual transport activities, better visibility, and increased transport throughput.

“Today, the entire process looks completely different. Production operators order components through the MES system, the warehouse prepares the required containers, and the transport process itself runs automatically. This has allowed us to increase the throughput of internal transport while reducing the number of activities related to moving materials manually.”

Damian Frątczak, Logistics Specialist, Borg Automotive

Safer, more organized production areas

One major outcome of the project is improved workplace safety. In the production areas served by the robots, forklift and pallet truck traffic has been eliminated, reducing vehicle movements and creating a more organized production environment.

“Safety is another important aspect. In the areas served by the robots, forklift and pallet truck traffic has been completely eliminated, creating an even more organized and safer working environment.”

Damian Frątczak, Logistics Specialist, Borg Automotive

Supporting people and preparing for growth

The automation supports employees by taking over repetitive transport work. Warehouse operators continue preparing production orders, while the autonomous mobile robots handle material transport between warehouse and production. That gives employees more time for work that directly supports manufacturing while helping ensure reliable material availability across the facility.

For Borg Automotive, the current system is also a platform for further development. The company sees the implementation as a foundation for continued improvement and future growth.

“This is only the beginning of the journey. We are already seeing the benefits of automating internal transport, and we still have room to further develop the solution. Most importantly, we have created a system that supports our people and helps us prepare for future challenges and continued growth.”

Michał Owczarek, AMR Project Manager, Group Supply Chain, Borg Automotive

About Borg Automotive

Borg Automotive is one of Europe’s leading independent automotive remanufacturers, with more than 50 years of experience and industrial-scale remanufacturing operations across multiple European production facilities.

The company’s production depends on a steady flow of components from warehouse to manufacturing. Different production areas need different parts throughout the day, and warehouse operators prepare components for many production orders. As volumes increased, Borg Automotive saw a growing need to make this internal flow more visible, consistent, and controlled.