How to Overcome Three Challenges of AGV Implementation

Summary

Automated guided vehicles (AGVs) have become popular in warehouses, manufacturing facilities and other large industrial buildings. Budgeting for these specialized machines is one step in the implementation process. However, decision-makers must overcome additional challenges that could disrupt anticipated success if not tackled.

Benefits of AGVs

AGVs can transport heavy items, protecting workers from muscle strains or accidents. They are also excellent for applications that require moving goods through specific routes during the workday. Using them can make employees more productive by raising overall output and reducing errors.
 
Many leaders link their AGVs to enterprise resource planning tools or warehouse management systems. This approach aids inventory management and item tracking, improving operational visibility.

Addressing the challenges of using AGVs in industrial environments

People hoping to benefit from implementing AGVs must understand common obstacles and the best ways to address them.

1. Power source suitability: Leaders should evaluate how to keep AGVs running throughout their intended applications. A good starting point is calculating how many hours they will be used during a typical day. Leaders should then investigate the available methods of powering the machines.
 
Many have integrated batteries that people can recharge as needed. Although that option has become widely used, it can also pose challenges because of the hazards charging cords may pose in highly trafficked areas. Process delays may also occur while people wait for the batteries to recharge.
 
Executives at a BMW Group factory dealt with this challenge by working with a wireless charging solution provider. They developed a method for recharging batteries while people continued to use the AGVs. This approach eliminated charging-related downtime.

2. Humans and AGVs sharing the environment: Safety is a frequently mentioned benefit of using AGVs and other automated industrial technologies. Leaders can lay the groundwork for that benefit by listening to workers’ feedback about implementing the vehicles to support their tasks rather than hinder them.
 
Some people worry machines will take their jobs. However, even the most advanced technologies have shortcomings. Although some excel at repetitive tasks, there are still numerous things humans can do better than machines. The best arrangements involve people working alongside AGVs.
 
Many challenges occur when leaders overlook the organizational and human-related changes the machines will bring. Even if AGVs optimize workflows, they occasionally show error messages or have other temporary issues. Managers should assign specific individuals to investigate the problems and create frameworks for reporting and resolving them.
 
Explaining to employees how their tasks may change due to the AGVs can also proactively address challenges. Better preparedness for new equipment and processes can ease the transition. Cobots are also widely used in industrial environments, and studying the human-equipment interactions in those cases can help leaders know what to expect.

3. Working out the implementation details: Finding the best AGV applications may be an in-depth process. However, thoroughness and patience allow people to scrutinize workflows and identify the best places for implementation, avoiding potential pitfalls later.
 
Executives can begin by deciding how many AGVs they will introduce and within what time frame. Will the initial usage occur as part of a vendor-supported trial? Can they implement the machines during a less busy time to give workers more time to adjust to new processes? Fortunately, people can install most AGVs faster than other material handling systems.
 
The AGV market has become larger. Although that gives leaders more choices, it also creates challenges as they try to differentiate between various options and select models that align with their requirements. Executives should consider the size of their facilities, the volume of goods and the number of people occupying the area at a given time. Those particulars will determine how many AGVs to use and which type.
 
Those overseeing the implementation must also study the respective specifications for each AGV to ensure they match the planned applications. In one case, an automotive manufacturer attempted to begin using AGVs. However, the chosen type was too complex, and people loaded them with materials that reached their weight limit. The machines required frequent resetting and other operator interventions. Careful planning and short-term trials can prevent these possibilities.

Create the conditions for AGV success

AGVs have become useful in many industrial environments. People considering using them should learn from the above examples and consider the best ways to tackle workplace challenges before proceeding.