AMR Fleet for Internal Transport in Industrial Manufacturing
Illustrative scenario based on real deployment patterns. Not sourced from a specific company.
Warehouse Profile
- Warehouse size
- 18,000 sqm
- Personnel
- 85 warehouse and production staff
- Current setup
- Manual forklifts and tugger trains
- Deployment type
- Brownfield
The Situation
Internal transport between production lines and the central storage area is handled by forklifts and manual tugger trains. Driver shortages force overtime and restrict throughput to human shift patterns. Any disruption to the transport workforce directly halts production supply.
Automation Approach
An AMR fleet is deployed for autonomous point-to-point transport of production containers and stillages. Robots navigate around personnel and the existing forklift fleet using onboard sensors and dynamic maps. No infrastructure rebuild is required. The WMS or ERP triggers transport tasks; the AMR system allocates robots in real time.
Expected Outcomes
- 30–40% reduction in internal transport labour requirement
- 24/7 transport capability without additional shift headcount
- Brownfield deployment completed within 6–9 months with minimal disruption
- Flexible rerouting when layout changes — no fixed tracks to rebuild
Is This Scenario Right for You?
- Deployment
- Brownfield
- WMS requirement
- Optional — AMR system can operate standalone
- Budget range
- EUR 600K–1.8M depending on fleet size
- Payback estimate
- 2–4 years
- Minimum scale
- Effective from approx. 8 robot-hours of transport per day
Relevant Vendor Types
AMR specialists: AGILOX, Jungheinrich. Industrial robotics with AMR range: KUKA.
Browse the Supplier Discussion GuideFrequently Asked Questions
What is the difference between AMR and AGV in a warehouse context?
AMRs (autonomous mobile robots) navigate dynamically using onboard sensors and maps, adjusting routes in real time around obstacles and people. AGVs (automated guided vehicles) follow fixed paths defined by magnetic tape, wires, or reflectors. AMRs are more suitable for brownfield environments where flexibility is required. AGVs are preferred for high-load, fixed-route applications.
How long does an AMR deployment take from decision to operation?
For a mid-sized manufacturing deployment (10–30 robots), expect 4–9 months from contract signature to full operation. This includes site mapping, fleet configuration, WMS integration (if required), safety validation, and operator training. Smaller deployments can go live in as little as 8 weeks.
What payload can warehouse AMRs typically carry?
Most warehouse-class AMRs carry between 100 kg and 600 kg per unit. Heavy-duty models, such as those from AGILOX, carry up to 1,200 kg. For loads above 1,500 kg, AGVs or automated forklifts are typically more appropriate.
Can AMRs operate alongside human workers safely?
Yes. AMRs are certified to operate in shared human spaces under ISO 3691-4 (driverless industrial trucks) and ISO 10218 (collaborative robots). They detect and avoid people using LiDAR and camera systems. Mixed zones require defined safety zones and speed limits, which are configured during deployment.
Readiness Considerations
- A WMS or ERP capable of dispatching transport tasks improves AMR fleet utilisation significantly.
- Minimum two shifts of regular internal transport volume is needed to justify core fleet investment.
- Floor plan should be reasonably stable. AMRs reroute around obstacles, but frequent structural changes add reconfiguration cost.
Supplier Questions to Ask
- QHow is fleet size calculated for our specific transport volume and layout?
- QWhat does WMS or ERP integration require from our side in terms of interface, data format, and IT resource?
- QHow are battery charging and fleet availability managed during multi-shift operations?
- QWhat happens when a robot encounters an obstacle it cannot navigate around?
Assumptions to Validate
- Actual daily internal transport moves and distance covered per forklift or tugger driver.
- Current labour cost per FTE including overhead, not only base salary.
- Fleet size estimates from at least two suppliers before committing to a business case.
- Shift structure impact: AMR assets run 24/7 but charging time affects available capacity.
When This May Not Be the Right Time
- No WMS or ERP in place. AMRs can operate standalone but utilisation and ROI are lower without task integration.
- Significant floor plan or layout changes are planned within the next 12 months.
- Transport volume is below approximately 8 robot-hours per day across all shifts.
Related Scenarios
Does this scenario match your situation?
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