AGVHub
AGV Implementation Process
Step-by-step guide for AGV projects: From the first idea to productive operation – phases, milestones, and typical timeframes.
Reading time: 3 min
Project Phases Overview
An AGV implementation typically goes through five phases:
1
Analysis & Concept
2-4 weeks
2
RFQ & Vendor Selection
4-8 weeks
3
Detail Planning
4-8 weeks
4
Implementation & Commissioning
8-16 weeks
5
Ramp-up & Optimization
4-12 weeks
Total Duration: Typically 6-12 months from decision to full operation.
Phase 1: Analysis & Concept
Tasks
- As-is analysis of current material flows
- Goal definition (throughput, availability, costs)
- Create rough layout
- Feasibility check
- Business case calculation
Deliverables
- Requirements document / specification
- Volume estimates
- Go/No-Go decision
Invest sufficient time in this phase. Thorough analysis prevents expensive surprises later.
Phase 2: RFQ & Vendor Selection
Tasks
- Finalize specification
- Identify and contact vendors
- Obtain and compare quotes
- Conduct reference visits
- Negotiations and contract signing
Evaluation Criteria
| Criterion | Weighting (Example) |
|---|---|
| Technical suitability | 30% |
| Price / TCO | 25% |
| References / Experience | 20% |
| Service & Support | 15% |
| Project management | 10% |
Phase 3: Detail Planning
Tasks
- Create detailed design (with vendor)
- Define travel paths and stations
- Specify interfaces (WMS, PLC, etc.)
- Develop safety concept
- Plan infrastructure (floor, WiFi, charging)
Key Stakeholders
- IT department (network, interfaces)
- Safety team (risk assessment)
- Works council (if applicable)
- Facilities management (construction)
Phase 4: Implementation & Commissioning
Process
-
Prepare infrastructure
- Floor remediation (if needed)
- Install reflectors / navigation aids
- Set up charging stations
- Configure network
-
Deliver & set up vehicles
- Delivery and assembly
- Basic configuration
-
Configure software
- Install fleet control
- Teach maps / routes
- Connect interfaces
-
Testing
- Function test of individual vehicles
- Integration test with peripherals
- Load test under real conditions
-
Acceptance
- Formal acceptance per specification
- Hand over documentation
- Conduct training
Phase 5: Ramp-up & Optimization
Tasks
- Gradual production start
- Observation and fine-tuning
- Route and parameter optimization
- Training additional staff
- Transition to regular operation
Plan for reduced operation during ramp-up. You won't achieve full productivity on day one.
Common Pitfalls
| Problem | Prevention |
|---|---|
| Underestimated floor issues | Early floor analysis |
| WiFi problems | Coverage measurement before start |
| Interface issues | Early IT involvement |
| Acceptance problems | Change management, communication |
| Unrealistic schedules | Build in buffers |
Conclusion
An AGV implementation is a complex project requiring careful planning. Take time for the analysis phase and work closely with all stakeholders.