What is AGV fleet sizing?
AGV or AMR fleet sizing determines the number of vehicles and operating strategy required to fulfil defined transport missions at the agreed service level.
Baseline calculation
Missions per period are multiplied by loaded and empty travel, pickup, set-down and positioning time. Waiting, charging, failure and maintenance reduce usable vehicle time. The calculated number is rounded up and checked against critical peaks.
When the baseline is insufficient
Intersections, blocked transfers, lifts, priorities, battery state and dispatching create vehicle interactions. Where these matter, the calculation is complemented by simulation within material-flow analysis.
Documented result
- transport matrix and reference period
- routes, distances and speed assumptions
- handling and waiting time
- charging and energy strategy
- availability and reserve
- service level and peaks
Further reading: AGV and AMR fleet-sizing guide.
Applying AGV fleet sizing in a project
AGV fleet sizing should combine average demand with peak windows, empty travel, handling, charging, traffic interaction and availability.
Before applying AGV fleet sizing, define the objective, system boundary and decision to be supported. The distinction from adjacent methods and systems is equally important: which processes are included, which interfaces remain outside the scope and which metrics indicate an improvement? This prevents a term from becoming a label and avoids local optimisation that creates new problems elsewhere.
A reliable assessment of AGV fleet sizing combines current-state data with documented assumptions. Sources, reference periods, units and exceptions need to be transparent. Alternatives or measures can then be compared using consistent criteria. Depending on the task, these include performance and cost as well as space, inventory, ergonomics, quality, feasibility, risk and expandability.
The output from applying AGV fleet sizing should support a concrete decision or a verifiable next step. Ownership, a target value and a review date make the expected effect measurable. To transfer the concept to a real assignment, connect it with the relevant consulting, planning, optimisation and digital capture services.
AGV fleet sizing in practice: Our services overview brings together the relevant planning and consulting approaches.