In this article, we highlight the three key mistakes to avoid when investing in AGV technology.
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Mistake 1: Automating a manual process ‘as is’
AGVs or other mobile robots can only do as they are programmed. If you haven't considered it, a robot cannot deal with it. This means tasks that would take only a minute for a human - such as moving a box that someone left in an aisle, or double-checking with a colleague before packing a rack - can cause an AGV operation to grind to an inefficient halt.
That’s why human-driven, manual processes can often not simply be automated ‘as is’. Instead, a process likely needs to be analyzed, simplified, and standardized before automating.
Do this instead: simplify before automating
Follow your existing processes from end to end. Imagine explaining them to a five-year-old (or a robot). Break them down into small, individual steps, and eliminate everything that isn’t essential.
One US company, GECOM Corporation, prepared its installation of F3 Nipper AGVs by asking staff to perform the full range of proposed automated processes using manual tow tractors first. Once these processes had been assessed and fine-tuned, the robots were simply slotted in place of the humans. Read the full case study.
Mistake 2: Don’t assume all AGV navigation systems are the same
AGV systems employ a wide range of different autonomous navigation technologies. Understanding the key differences between these technologies will ensure you select an automated guided vehicle that is reliable, accurate, and suits your company's application.
For example, AGVs that follow a physical line on the floor – such as magnetic tape or inductive wires – are highly accurate, as well as simple to understand and operate. However, they are relatively inflexible: their installation can take time (and money), their routes can become damaged are not quick to modify, plus these systems are inherently limited when it comes to operating a fleet and managing traffic.
If the process you are looking to automate is simple, such as a single-loop production line, a line following AGV may be perfect for the job. But if your processes are more complex, or your operation may need regularly modifying to adapt to an evolving site, other, more modern navigation technologies could be a better choice.
Laser triangulation is one such approach, but this requires significant installation time and therefore cost.
For a solid balance of quick installation, high accuracy and fleet-friendly scalability, we recommend AGV systems driven by natural navigation (such as ANT natural feature navigation).
Plus, it’s possible for vehicles powered by ANT natural feature navigation to accurately navigate outdoors with the product extension ANT everywhere.
Do this instead: research navigation systems
The navigation system that drives an AGV will have a large impact on its performance and therefore the success of your automation project. Therefore, make sure you fully understand the pros and cons of the different technologies on offer.
Mistake 3: Don’t assume robustness and accuracy
The number of AGV suppliers in the market has increased exponentially in recent years. However, a significant portion of these new manufacturers' systems falls short in terms of the robustness and accuracy they can achieve.
What does this mean for your investment?
Material handling applications usually require a decent level of both accuracy (around 1 cm or a half-inch is usually more than enough) and flexibility (in terms of being able to update routes and vehicle actions easily).
If your AGV’s positioning accuracy is weak, some basic applications may work but many typical logistics applications will simply not be possible.
If, for example, your application requires the picking and dropping of payloads, or if an AGV must move under racks or trollies to pick these up, solid positioning accuracy will be vital. Your AGV system will also need a certain level of accuracy to dock correctly with automatic charging stations, allowing fully autonomous operation (otherwise you might need to add an additional line following piece at such key locations in order to achieve the accuracy required).
Bear in mind that the vehicle accuracy you require must also be highly repeatable. Certainly don't place all your trust in a supplier's all-singing, all-dancing demonstration at their facility. There are plenty of horror stories in the industry about AGV or AMR demos looking great but then - once paid for - these technologies falling well short in real-life commercial use.
Do this instead: check the references
Before working with a vehicle supplier, check how long the company has been in business and how many vehicles they have in operation, today, at client sites.
It may not be possible to speak to another customer (although that would be ideal), but a supplier should supply several references and case studies. Or at the very least a list of client names relevant to your industry.
I. The Cost of Autonomous Forklifts
With labour shortages and rising operating costs, more companies are adopting self-driving forklifts to optimise their logistics and warehouse operations. These forklifts can increase efficiency, reduce human error, and improve workplace safety.
I'm sure you already know some of the basics, like what an automated forklift is and the different types of robotic forklifts. But how much do they cost? Let's dive into the price of an automated forklift! From upfront costs to hidden costs, this guide will help you understand this transformative investment.
Ⅱ. What Is the Difference? Automated Forklift vs Fork AGV
An automated forklift is a vehicle that lifts autonomously, and these vehicles often have hybrid capabilities, meaning they can be operated autonomously or driven manually as needed. Automated forklifts are sometimes referred to as Automated Guided Forklifts (AGF), Forklift AGVs, or Driverless Forklifts.
Fork AGVs are Automated Guided Vehicles (AGVs) with forks. These vehicles are designed for automated driving.
Ⅲ. What Factors Affect the Cost of an Automated Forklift?
Several major factors affect the initial purchase price of an AGV:
1. Payload capacity
How much weight can it carry? The higher the payload, the higher the cost.
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2. Lift height
How high can it carry the load? The higher the height, the higher the cost.
3. Navigation technology
The cost of laser, vision, inertial and magnetic navigation systems varies greatly.
4. Software
More powerful and add-on software usually increases the cost (sometimes it is overpowered for the task at hand)
5. Safety systems
There are no mandatory AGV safety standards for self-driving forklifts. In Europe, for example, they only need to comply with the CE marking. This means that a forklift truck from one supplier may be equipped with only 1 safety scanner, while a vehicle from another supplier is equipped with 3 or more safety scanners. Then there are some other protection requirements. For example, if you wish to detect protruding objects above the ground, additional AGV sensors such as LIDAR, ultrasonic sensors or radar may be required, which can increase the cost of the vehicle.
6. Customisation
Integration with existing software systems and specialised profiles or configurations can significantly increase costs.
7. Support options
Technical support, user and maintenance training, maintenance contracts and extended warranties can all add to costs
8. Brand Reputation
Established equipment manufacturers often have higher pricing
Before investing in AGVs for your factory, there are some key points to consider that affect the cost: how many vehicles are needed? What kind of AGV should be used, and what is the complexity of the installation? What are the vehicle dimensions? What is the load capacity? What is the load capacity? - All of these have an impact on the cost of an AGV installation.
In addition to the purchase price, companies should consider the following costs: maintenance and repairs, energy costs, software and integration.
V. How Long Does It Take to Get a Return on the Use of AGV Automated Forklifts?
For factories operating two or three shifts per day, most companies can expect to recoup their initial investment in AGVs within two years. And those plants operating three shifts may be able to fully recoup their investment in less than a year, with some companies even recouping their AGV investment in a matter of months. (Yes, really!)
Key factors affecting payback time include:
- Hours of operation - more shifts lead to faster returns
- Labour costs - higher wages mean quicker break-even points
- Productivity gains - automated systems optimise workflow and eliminate downtime, increased production equals increased revenue
- Safety impact - Reduced risk of accidents, lower insurance costs and improved workplace compliance
- Flexibility - Basic AGVs can be easily redeployed to where they are needed most, increasing the value of agility
- Quality Improvement - Reduced errors and damage increase profits
- Scalability - organisations can expand their fleet without worrying about recruitment challenges.
Round-the-clock operation means the AGV continues to move tools, products, materials, bedding, and more even after workers have left work. Workers can return to the production line the next day fully loaded and ready for maximum productivity.
Remember, there are additional costs associated with keeping people on the job. The increased risk of accidents means higher insurance costs - and, of course, actual accidents can cause huge expenses. This makes accident-prone areas, such as blind corners, narrow areas near conveyors and densely packed production lines, an ideal opportunity for automation and a quick return on investment.
Ⅵ. The Application of AGV Automatic Forklift Trucks
The way AGVs are used depends on the use case and the needs of the end user. Most cases focus on transporting, delivering and storing various materials in warehouses, manufacturing and logistics centres. These operations are carried out without human assistance, ensuring that production lines are always managed accurately.
These systems are increasingly used in many industries such as:
- Automotive
- Beverage/Food
- Consumer Goods
- Healthcare/Pharmacy
- Industrial manufacturing
- Retail and e-commerce fulfilment
- Others
Regardless of the industry, innovative navigation systems that enable vehicles to manoeuvre automatically can optimise operational processes.
VII. Will Automated Forklifts Replace Human Operators?
Analysts predict strong growth in the forklift automation market through . However, complete replacement of human operators remains unlikely. Most warehouses will have a mixed model of automated forklifts and certified human operators. Even in automated environments, human supervision will remain critical. U.S. Occupational Safety and Health Administration (OSHA) regulations still require operators to be certified to supervise or manually operate forklifts, whether conventional or automated.
VIII. Conclusion
So sorry I can't provide an accurate price for an automatic forklift because there are so many factors to consider. However, I hope this article has helped you understand. I recommend that you contact AiTEN Robotics for a more detailed analysis.
In the meantime, if your business relies on high-volume material handling, then an automated forklift is a strategic investment that can significantly improve efficiency, reduce operating costs, and ensure long-term scalability.
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