DATE: 2025/11/28

Revolutionizing Smart Warehouses: How SEER Robotics Powers ZF Automotive’s Dark Factory

As night falls over ZF Automotive Systems (Shanghai) Co., Ltd.’s Jiading District facility, the warehouse remains dark—but production never stops. Agile robots move seamlessly, accurately picking and placing goods, enabling a fully unmanned operation process.

This is the reality of ZF’s Dark Factory, recognized as a National Exemplary Smart Factory. At the heart of this intelligent operation is the one-stop robot solution provided by SEER Robotics.

Project Challenges: Why Traditional Automation Fell Short


For a leading automotive parts manufacturer like ZF, advancing toward a fully automated warehouse came with multiple hurdles:

  • Varied Material Specifications: Different sizes and types of goods made manual handling inefficient and prone to errors.
  • Complex On-Site Environment: The warehouse required extremely high laser positioning accuracy for safe and precise robot navigation.
  • Rack Limitations: Structural constraints meant not all types of goods could fit in every storage unit.


SEER Robotics Solution: More Than Just Robot Replacement


SEER Robotics delivered a highly integrated, open, and collaborative smart logistics system—not merely a robot replacement. By leveraging SEER’s intelligent control system, ZF achieved streamlined automation with full traceability and operational efficiency.

1. Intelligent Traffic Control: Seamless Multi-Robot Collaboration

  • Manages ground forklifts, stacking forklifts, and other robotic units
  • Real-time path planning and dispatch to prevent congestion and deadlocks
  • Ensures smooth logistics across workshops, production lines, gate crossings, and charging stations

2. Robot Brain + Business Brain: Breaking Down Information Silos

  • Integrates robot systems, M4 business brain, and on-site automated equipment
  • Achieves unified plant management, precise material tracking, and full traceability
  • Intelligent allocation of storage heights based on customized rules
  • Resolves challenges from varying material specifications

3. Open Compatibility: Precise Navigation in Complex Environments

  • Customization through open interfaces addresses laser positioning challenges
  • Laser positioning blocks and optimized algorithms improve robot navigation accuracy
  • Guarantees precise operation even in complex warehouse layouts


Customer Recognition: Real Results from Real Users


Alex, Lean Production and Automation Lead:
"The SEER Robotics system provided critical support for building the Dark Factory, accelerating lean production, and achieving a dual leap in efficiency and value creation."

Cathy, Warehouse Manager:
"From receiving and storing to retrieving and shipping, the process is now fully automated. Inventory accuracy has reached 100%, and personnel efficiency has reached new heights."


Why This Matters: Key Value of SEER Robotics


  • Faster ROI: Build your own robot fleet within days and see immediate impact on production efficiency.
  • Scalability: Open and collaborative system allows easy integration of new robots or modules.
  • Reliability: High-precision navigation ensures safe, uninterrupted operations.
  • Enhanced Accuracy: Full traceability and intelligent allocation reduce errors and optimize warehouse space.


Q&A: Understanding Smart Warehouse Transformation


Q1: How quickly can a company implement a SEER Robotics solution?
Companies can build their own robot fleet within days, thanks to SEER’s modular and flexible platform.

Q2: Can this system handle complex, multi-spec material management?
Yes, the integrated robot and business brain system ensures full traceability and customized storage allocation, even for highly diverse inventory.

Q3: Is it compatible with existing warehouse infrastructure?
Absolutely. Open interfaces and precise laser navigation allow seamless integration with existing racks, conveyors, and automated equipment.


Conclusion


By leveraging SEER Robotics, ZF Automotive’s Dark Factory exemplifies the future of smart warehouses, combining efficiency, precision, and flexibility. With modular solutions, multi-robot collaboration, and intelligent logistics management, companies can achieve fully automated operations, optimized space utilization, and significant production gains.