Highlite International B.V. chooses Toyota’s Swarm Automation for efficiency and safety
As a wholesaler in show electronics, Highlite faced the challenge of absorbing peaks and troughs in their business processes and achieving their expected growth with a small team. Thanks to the choice of advanced automation, with the integration of 3 AGVs, they have perfectly addressed this challenge.
About Highlite
Highlite International B.V. is a wholesaler in show electronics for the entertainment industry and distributes to more than 80 countries. Highlite represents brands in solutions for audio, show light, professional lighting, stage effects, video playback and stage supplies. With a warehouse covering more than 25,000 m2 of storage space, Highlite guarantees high availability and fast delivery.
Facts and figures
Company: Highlite International B.V.
Location: Kerkrade, The Netherlands
Industry: wholesale
Solutions: 3 AGVs (automated stacker SAE), Toyota VNA truck
A hybrid solution
To meet the challenges of fluctuating demand and anticipated growth, Highlite International B.V. made a strategic decision to automate their warehouse operations. With a lean warehouse team of just 20 people, it was essential to implement a system that could absorb peaks and troughs in order volume without compromising efficiency or accuracy. Swarm Automation has empowered Highlite to maintain consistent throughput, even during high-demand periods, while keeping the workforce streamlined.
At the heart of this particular automated solution are three Automated Guided Vehicles (AGVs), which operate across eight designated stops where they either retrieve or drop pallets. What makes this setup particularly efficient is its seamless integration with Highlite’s existing automation infrastructure and operational workflows. The AGVs collect pallets from a conveyor system and transport them to a buffer zone, where a very narrow aisle (VNA) truck takes over. This truck then brings the pallet to its correct location. Combining two distinct technologies (i.e. AGVs and VNAs) into one cohesive system results in a hybrid solution that maximises both flexibility and efficiency.
Automation bringing calm and order
Before implementation, the warehouse was a hive of manual activity, often chaotic, where it was difficult to navigate the narrow layout, making it a high-risk environment for accidents and inefficiencies. “Since completion of the project, the transformation has been remarkable,” says Lex van Zwieten, Sales Development Manager at Toyota Material Handling NL,
“The warehouse is now a calm, orderly space with clear traffic flows and minimal congestion. This has significantly improved safety and visibility, allowing the team to work more confidently and effectively.”
Moreover, the integration between Toyota VNAs and Highlite’s Warehouse Management System (WMS) has introduced two major advantages: optimised routing and simplified onboarding. Firstly, the VNAs autonomously calculate the most efficient paths between picking and drop-off points. Compared to manual labour this is a much more efficient way of working. A second benefit is when new employees are hired, the system is so intuitive that training takes just 30 minutes, allowing operators to become productive almost immediately.
Continuous improvement
Choosing the right automation partner was critical to the success of this project. As Ruud Segers, Service & Supply Chain Manager at Highlite International explains: “In our search for an automation partner, we selected a partner who doesn’t just offer a product but actively participates in shaping the solution and contributes ideas. Toyota Material Handling’s approach to continuous improvement left room for making incremental enhancements throughout the project.”
“While we outlined the main goals and requirements,” he continues, “Toyota’s consultants brought fresh perspectives and maintained the flexibility to adapt as new insights emerged. This collaborative approach fosters trust and ensured that the final system delivered is not only technically sound but also tailored to our unique operational needs.”
“We are very proud of this result,” Ruud concludes, “Five years ago, I could never have imagined that we’d already be driving this now. During this project we have experienced the cooperation with Toyota Material Handling as very positive.”