AGVHub
Common AGV Implementation Mistakes
The 10 most common mistakes in AGV projects and how to avoid them. Learn from others' experiences.
Why Do AGV Projects Fail?
Not every AGV project becomes a success. Often it's recurring mistakes that could have been avoided. Here are the most common pitfalls:
The Top 10 Mistakes
1. Unclear Requirements
The Problem
Vague specifications, no clear volume data, fuzzy goal definition.
The Solution
Detailed specification with measurable requirements. Data-based volume analysis over several weeks.
2. Underestimated Floor Condition
The Problem
Cracks, bumps, joints – the floor is worse than expected.
The Solution
Professional floor analysis BEFORE the RFQ. Budget for remediation.
3. IT Department Involved Too Late
The Problem
WiFi insufficient, firewall blocks, interfaces not clarified.
The Solution
Include IT in project team from the start. Commission WiFi survey. Clarify interface specs early.
4. Only Looked at Vehicle Price
The Problem
Cheapest vendor wins – but service, software, and integration cost extra.
The Solution
TCO analysis (Total Cost of Ownership) over 5+ years. Include maintenance, parts, training.
5. Skipped Pilot Project
The Problem
Ordered 20 vehicles directly without testing the technology in your own environment.
The Solution
Start with 1-3 vehicles. Gather experience, then scale.
6. Employees Not Engaged
The Problem
Workforce resistance, sabotage, lack of acceptance.
The Solution
Communicate early, take concerns seriously, train and involve employees.
7. Unrealistic Timeline
The Problem
"Everything must run in 3 months" – and then commissioning delays by months.
The Solution
Realistic schedules with buffers. 6-12 months is normal for an AGV project.
8. Underestimated Interfaces
The Problem
WMS connection fails, doors don't open automatically, conveyors don't communicate.
The Solution
Define all interfaces in specification. Clarify responsibilities. Allow sufficient testing time.
9. No Reserve Capacity Planned
The Problem
System runs at 100% utilization – any disruption causes complete breakdown.
The Solution
Plan 20-30% reserve capacity. Think through failure scenarios.
10. Maintenance Neglected
The Problem
After commissioning, nobody takes care of the vehicles – until they fail.
The Solution
Sign maintenance contract. Define internal responsibilities. Regular inspections.
Conclusion
Most mistakes originate in the planning phase. Invest time in thorough preparation, involve all stakeholders, and plan realistically.