P&G Warehouse Automation Robot - Industrial AGV System
This project was a comprehensive Automated Guided Vehicle (AGV) system proposal designed for Procter and Gamble Egypt to solve inefficient manual pallet transport across 8 production lines. Khaled led a 4-person university team that designed the full autonomous system including WiFi RSSI indoor localization, Hadlock/Soukup path planning algorithms, barcode verification, and swarm coordination. The proposal included 3D mechanical designs, an 18-page technical document, flow charts, and cost estimation. While the proposal was accepted and funded, it was never implemented due to the client losing interest in follow-through.
Problem Solved
Manual pallet transport across 8 production lines with 3 storing lines each was inefficient and required excessive human interface in the storage system
- •Led 4-person multi-disciplinary university team
- •Designed 3D mechanical systems in SolidWorks including drive system and payload handling
- •Developed control system architecture using C programming
- •Implemented WiFi RSSI indoor localization algorithm with 4-beacon triangulation
- •Created Hadlock/Soukup path planning algorithm with 50cm grid resolution
- •Produced 18-page technical proposal with flow charts, cost estimation, and demo video
- •Presented proposal to P&G Egypt stakeholders
- ✓Led university team to design complete AGV system for real industrial client (P&G Egypt)
- ✓Proposal accepted and funded by major multinational corporation
- ✓Implemented WiFi RSSI indoor localization achieving reliable position tracking with 4-beacon triangulation
- ✓Developed Hadlock/Soukup path planning algorithm optimizing for shortest path with minimum rotations
- ✓Created 3 solution scenarios with cost estimates ranging from $19,134 to $19,705 per unit
- ✓Designed comprehensive safety systems including obstacle detection and automated charging
- ✓Produced professional 18-page technical proposal with flow charts, CAD models, and demo video
Performance
- • 50cm grid resolution for path planning
- • 30-second obstacle wait protocol
Scale
- • Designed for 8 production lines with 3 storing lines each
Technology Stack
Challenge
Indoor localization without GPS in warehouse environment
Solution
Implemented WiFi RSSI triangulation using 4 beacons at 20m radius coverage, calculating position from signal strength ratios
Impact
Achieved reliable indoor positioning for autonomous navigation
Challenge
Efficient path planning in dynamic warehouse with obstacles
Solution
Developed Hadlock/Soukup algorithm with 50cm grid resolution, optimizing for shortest path with minimum rotations
Impact
Created smooth AGV movement patterns suitable for heavy payload transport
Challenge
Precision alignment for loading and unloading at stations
Solution
Designed dual laser emitter/receiver system with 48 sensor pairs for millimeter-accurate positioning
Impact
Enabled reliable automated pallet transfer at production and warehouse stations
Challenge
Converting proposal acceptance into actual implementation
Solution
Delivered comprehensive technical documentation and cost estimates to facilitate decision-making
Impact
Proposal was funded but ultimately not implemented due to client losing interest
Situation
Procter & Gamble Egypt operated 8 production lines, each with 3 storing lines, requiring extensive manual pallet transport to the warehouse. This manual process was inefficient and the company sought to minimize human interface in their storage system. As a university student, Khaled saw an opportunity to apply robotics knowledge to a real industrial problem.
Task
Khaled led a 4-person university team to design a complete Automated Guided Vehicle system that could autonomously transport pallets from production lines to warehouse storage, including indoor localization, path planning, and safety systems.
Action
The team developed a comprehensive solution starting with WiFi RSSI indoor localization using 4-beacon triangulation to track AGV position without GPS. The Hadlock/Soukup path planning algorithm was implemented with 50cm grid resolution to find optimal routes while minimizing rotations. Mechanical designs were created in SolidWorks including a tank-style drive system and elevating conveyor for pallet handling. Three solution scenarios were developed with detailed cost estimates. The team produced an 18-page technical proposal with flow charts, CAD models, and a demo video for presentation to P&G stakeholders.
Result
The proposal was accepted by P&G Egypt and won funding, validating the team's ability to design production-grade industrial automation systems while still university students. Although the project was never implemented due to the client losing interest in follow-through, the experience provided invaluable exposure to industrial robotics, client engagement, and technical proposal development. This became the first real industrial client project, demonstrating capability to design comprehensive automation solutions.
Technical
- • Industrial robotics system design
- • Indoor localization techniques (WiFi RSSI)
- • Path planning algorithms (Hadlock/Soukup)
- • SolidWorks mechanical design for industrial applications
- • Control systems programming in C
- • Sensor integration and fusion
Soft Skills
- • Technical proposal writing and cost estimation
- • Client presentation and requirements gathering
- • Multi-disciplinary team leadership
- • Working with corporate clients
Key Insights
- 💡 Winning a proposal does not guarantee implementation
- 💡 Industrial automation requires comprehensive safety considerations
- 💡 Real clients provide invaluable experience even when projects are not implemented