At its production site in Affalterbach, Germany, Mercedes-AMG has automated key warehouse processes with a tailored AutoStore solution and material flow concept designed by Element Logic. 

About Mercedes-AMG

Based in Affalterbach, Mercedes-AMG is the performance and sports car brand of Mercedes-Benz. Founded in 1967 as an engineering office focused on racing engines, the company quickly established itself in motorsport, achieving a class victory and second place overall at the 24-hour race in Spa as early as 1971. 
 

Since 2005, Mercedes-AMG has been a wholly owned subsidiary of Mercedes-Benz AG and has evolved into a key force behind performance engineering within the group. The Affalterbach site brings together core functions including development, testing, design, and production, as well as the AMG engine manufacturing facility. 

Automating production supply for V8 manufacturing

To improve efficiency in material supply for V8 engine production, Mercedes-AMG automated its storage and picking processes with a compact AutoStore solution.  

Element Logic was selected as the partner responsible for both concept development and project implementation. 

“By leveraging the existing building structure, we developed a forward-looking material flow concept that convinced the decision-makers at Mercedes-AMG,” explains Joachim Kieninger, Director Strategic Business Development at Element Logic Germany. 

“We were able to demonstrate that the solution, with clearly separated material flows, handles the required tasks of assembling and storing production kits efficiently.”

Joachim Kieninger, Director Strategic Business Development at Element Logic Germany. 

Integrating existing infrastructure 

For the Mercedes-AMG, our team implemented a system with capacity for 8,200 bins, stacked up to sixteen levels high, with 48 robots managing all storage and retrieval processes. 

Inbound processes are handled via three Conveyor Ports on the ground floor, achieving throughput of up to 390 bins per hour for components used in engine production, while six additional ports supply production with up to 1,300 assembly kits per hour. 

To make full use of the available space, an existing mezzanine was fully integrated into the material flow design. Here, assembly kits are prepared according to the production schedule across four combined workstations, each consisting of one Carousel Port and four Conveyor Ports. 

Items are delivered to the workstations for picking and consolidating into target bins using a pick-to-light system. The completed kits are temporarily stored in the AutoStore and retrieved on demand at ground level, where they are transferred to a tugger train for delivery to the relevant production stations. 

Seamless processes and system integration 

To support quality assurance, three additional Conveyor Ports are installed on the mezzanine for regular visual inspections. 

Warehouse operations run smoothly through the integration of Mercedes-AMG’s own warehouse software, implemented as part of the overall solution. 

This project demonstrates Element Logic’s role not only as a system integrator, but as a partner delivering fully integrated automation solutions from concept and design to system integration and long-term operational support. 

Reliable material supply to assembly stations 

Since spring 2025, the solution at the Mercedes-AMG logistics facility has been reliably supplying component kits to assembly stations. 

To ensure continuous system availability and ongoing maintenance, Mercedes-AMG and Element Logic have also entered into a five-year service level agreement. 

“We at Element Logic are genuinely proud of the solution we have developed and implemented for Mercedes-AMG,” concludes Kieninger. “Overall, this project once again demonstrates the exceptional flexibility of AutoStore technology.”