When Autonomous Technology Works: An Inside Look at Honda's Fleet of Self-Driving Factory Robots

      Byron Hurd

      Following years of public “beta” testing of its Full Self-Driving feature, Tesla appears only marginally closer to rolling out fully autonomous robotaxis to the wider market. But what if I mentioned that self-driving vehicles have consistently been proving their capabilities, accumulating millions of miles, documenting hours, and enhancing processes without you realizing it? Welcome to the realm of industrial automation, where robots have been in control for decades.

      I witnessed this firsthand during my visit to Honda’s Marysville Auto Plant in late January, where the company is starting to implement Automated Guided Vehicles (AGVs) on its now-electrified production line. Along with Autonomous Mobile Robots (AMRs), they are gradually transforming manufacturing and logistics processes.

      Honda

      While AGVs and AMRs are distinct, they share similarities; AGVs depend on a form of guidance, whether through a predetermined route or physical and digital markers, while AMRs can operate more freely—similar to consumer vacuum or lawn-mowing devices. How many of these self-driving robots exist? For context: Of approximately 2.7 million cars Tesla has sold since its founding, only about 500,000 owners have ever engaged with Full Self-Driving. In contrast, the AGV/AMR market accounts for millions of units sold annually.

      Much of the technology previously considered implausible for self-driving cars proves to be highly applicable in a factory setting, where it's possible to paint lines, place reflectors, or even print data matrix codes (akin to QR codes) that illuminate a digital pathway with minimal reliance on additional guidance equipment. Honda’s AGVs (such as the blue one shown above) navigate Marysville’s prototype battery assembly line by simply following a guide adhered to the floor. If Honda determines that the current route isn't the most efficient, it’s simply a matter of laying down new vinyl.

      Byron Hurd

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      Whether it’s in a vehicle or on the manufacturing floor, a prominent critique of autonomy is its potential to diminish the human element. If we simplify this concept to a more charged assertion, we might reach the more politically sensitive conclusion that robots are displacing jobs. Historically, this has had some validity, but in today’s factories and warehouses, good help has been hard to come by. It may seem counterintuitive (or even at odds with popular narratives), yet an increasing number of customers are acquiring AGVs and AMRs to complement the human roles they struggle to fill.

      This was not necessarily the prevailing situation even 10 or five years ago, as Rocrich AGV Solutions president Brian Spradlin explained to me during a call this week, but it is certainly the case now. More clients are opting for robots due to their reliability and consistency, despite the significant upfront investment they may require.

      Porsche

      Furthermore, AGVs and AMRs enhance safety. While touring the Marysville plant, I was struck by the notable absence of a common fixture in manufacturing and logistics settings: the forklift.

      When I queried Spradlin about the industry's stance on forklifts, he acknowledged that safety for operators is a significant concern with human-operated forklifts. Though even manned tugs and other human mobility solutions can be hazardous, forklifts are almost inherently precarious due to their design, which necessitates balancing various large loads well above their center of mass. In my opinion, they’re cumbersome machines (my description, not his) operated by unpredictable humans (again, my characterization). We've all seen the videos—there's a reason you can’t just hop on one and start using it.

      Despite the exaggerated tone, operators have genuine concerns. This again highlights the reliability of automated systems. Robots do not tire, become fatigued, or get distracted by conversations or disruptions. Another win for machines, right?

      However, even if the AGV can perform the forklift operator’s tasks more safely, it lacks an essential aspect that cannot be replicated: human judgment. While human judgment can be fallible, it remains crucial. A human can identify when a container is covered by a shipping blanket or if there’s an empty coffee cup on top, whereas a robot merely detects an unfamiliar shape, potentially causing it to halt and await human assistance. For the foreseeable future, there will be no replacement for a discerning eye—a human eye.

      So, what is limiting AGVs from becoming the next “big thing?” When I asked Spradlin this question, he noted that the focus is less on breakthroughs in core technology at this stage and more on adapting it to newer, more dynamic environments. A significant challenge for AGVs and especially AMRs is operating outdoors. American autonomous vehicle manufacturers primarily conduct their testing in the Southwest or California, where the weather is predictable and does not typically include snow, which can incapacitate camera-based systems. As the industry discovers ways to adapt to challenging weather, new opportunities for automation will emerge. I