Understanding AGVs (Automated Guided Vehicles) in 5 minutes: Explaining the differences with AMRs, driving methods, transport methods, and benefits of implementation.

The logistics industry is facing significant labor shortages, and one promising solution that has garnered attention is the use of Automated Guided Vehicles (AGVs), also known as unmanned transport robots. AGVs offer numerous benefits, including reducing employee workload and minimizing errors. However, it's important to note that there are cases where the expected benefits of AGV implementation may not be fully realized. In this article, we will explain the mechanics of AGVs, highlight the differences between AGVs and Autonomous Mobile Robots (AMRs), and discuss the benefits and challenges of AGV implementation.

What is an AGV?

AGV stands for ""Automatic Guided Vehicle,"" also known as unmanned transport vehicles or robots. AGVs can be described as wheeled robots that transport goods in place of humans. They can carry loads and tow items while traveling. In the warehouse and factory sectors of the industrial world, the movement of goods is essential. Traditionally, goods were transported using methods such as forklifts or carts. However, with advancements in technology and a shortage of labor, AGVs have become a focus of attention in the logistics industry.

In recent years, there has been a significant increase in consumer purchasing behavior through e-commerce, leading to a surge in the number of distributed products. Consequently, the logistics and warehouse industry is flourishing, but it continues to face chronic labor shortages.
According to a survey by the Ministry of Land, Infrastructure, Transport and Tourism, the number of handled parcels for home delivery increased by approximately 20% in the five-year period from 40.2 billion units in 2016 to about 48.4 billion units in 2020. This increase has put a heavy burden on the industry.


To address these changes in the industry, labor shortages, and the need for efficiency, manufacturers have developed various automation devices. Among them, AGVs, the unmanned transport vehicles, have emerged. AGVs automate the transportation of goods, replacing the need for human involvement.

When tasks are performed by humans, there is always a possibility of errors or time delays due to fatigue. AGVs, being robots, can mitigate such risks and contribute to labor reduction and productivity improvement. AGVs have been used in manufacturing environments since the 1990s, and their utilization has increased over the years due to advancements in technologies like lithium-ion batteries.

AGVs complement human efforts by taking care of transportation time and the labor involved. They hold the potential to alleviate labor shortages. The use of AGVs is not limited to the logistics and warehouse industry; they are also widely adopted in warehouse and production facilities. Over the past decade, an increasing number of companies have implemented AGVs.


Trends in AGV Deliveries in Japan

Differences between AGVs and AMRs

There is another similar technology called AMR, which stands for ""Autonomous Mobile Robot."" AMRs are autonomous transport robots that differ from AGVs in their operational approach.
While AGVs follow predetermined routes using guidance systems such as magnetic tapes or 2D codes, AMRs are equipped with sensors that enable them to autonomously determine their position and navigate their routes. In simple terms, AMRs operate with autonomy, while AGVs operate with guidance.

Differences in Guidance Systems (Methods of Travel) between AGVs and AMRs

AGVs have two main types of guidance systems: ""magnetic induction/line tracing"" that utilizes magnetic tapes installed on the floor, and ""landmark"" that reads 2D barcodes. AGV implementation requires floor modifications and follows predetermined routes, making the definition of usage requirements and layout design crucial. Considerable preparatory work is necessary.

On the other hand, AMRs employ Laser SLAM (Simultaneous Localization and Mapping) for mapping, allowing for direct installation without floor modifications. Most AMRs utilize Laser SLAM, which enables free movement once map data is acquired. Since they do not require guidance systems such as magnetic tapes or 2D barcodes, AMRs can be implemented without floor modifications. They have the capability to detect and avoid humans and obstacles, facilitating collaborative work with humans.

Different Utilization Methods of AGVs and AMRs

Based on the differences in functionality, AGVs are suitable for large warehouses where goods need to be transported from point A to point B or point C following predefined routes. However, it is essential to consider that AGVs require floor modifications, making layout changes challenging.

AMRs, on the other hand, have a different development concept compared to AGVs. While AGVs have a role as transport vehicles following predetermined routes from point A to point B, AMRs are designed to collaborate with humans. Therefore, AMRs are suitable for environments with a significant number of personnel, such as factories and warehouses.

A specific use case of AMRs is their ability to read picking lists and independently determine routes to the locations where the desired items or components are stored. Humans assist by picking the items and handing them to the AMRs. Subsequently, the AMRs follow the next instructions and move accordingly.

Additionally, one advantage of AMRs is that they do not require floor modifications. In factories, layout changes and variations in workforce are common due to product specification changes and production variations. Similarly, in logistics warehouses, changes in handled products and variations in space occur regularly. AMRs, which do not require floor modifications, can flexibly adapt to layout changes and the addition of units. However, it is important to note that AMRs with advanced features tend to have higher costs.

Three Methods of AGV Transport

AGVs not only differ in their modes of travel but also in their methods of transport. The main methods of AGV transport are as follows

Trolley-Type AGV

This method involves directly loading goods onto an AGV that resembles a handcart. It is suitable for transporting items with shapes that are less likely to fall off the cart, such as cardboard boxes or box-shaped containers. It is commonly used for transporting goods to storage locations or for delivery arrangements.

Towing-Type AGV

In this method, an AGV is connected to a cage trolley or pallet trolley and tows it for transport. It allows for the transportation of multiple connected cages or heavy loads. It is often used when transferring components from one building to another within a factory after inspection.

Low-Profile AGV

This method involves fitting underneath shelves or pallets and lifting them for transport. It is useful when transporting items that lack wheels or when there is no connection point for towing on the cart. It is commonly used in processes where multiple required items need to be moved at once, such as moving shelves storing parts required for picking to picking stations.

For more information on AGV transport related to shelf transport AGVs, please refer to the ""Case Studies: Automation with Shelf Transport AGVs"" page.

Three Benefits of AGV Implementation

Regardless of the differences in travel and transport methods mentioned above, implementing AGVs offers several benefits. The main benefits include the following

Benefit 1: Reduction of Worker Burden

When manually transporting goods, workers need to walk around large factories or warehouses to locate and pick items. They may also have to pull heavy carts weighing hundreds of kilograms or transfer large components. These tasks can place a significant burden on workers. By introducing AGVs, workers no longer need to walk around for transport or handle heavy carts, leading to a substantial reduction in their workload.

Benefit 2: Mitigation of Labor Shortages

As mentioned earlier, the reduction in worker burden can enable workforce reduction. The logistics industry is facing significant labor shortages due to factors such as the aging population. Implementing AGVs can help alleviate labor shortages. Moreover, if there is a surplus of personnel in warehouses or factories, they can be reassigned to other departments, allowing for overall optimization of personnel allocation within the company.

Benefit 3: Reduction of Human Errors

Reliance on human labor for transport tasks often leads to human errors, such as picking the wrong products. These errors are particularly common among inexperienced employees or those fatigued from physically demanding transport tasks. By minimizing human involvement through AGV implementation, these human errors can be significantly reduced. The reduction of labor and human errors can lead to increased productivity and long-term cost savings.

For more information on reducing human errors, please refer to the following article

Process of AGV Implementation

Implementing AGVs involves considering various environmental factors. A site survey is conducted to assess factors such as the types of transported goods, the condition of the floor surface, and the narrowest areas along the routes where immovable equipment is located. Based on the survey findings, the implementation design, including the AGV's capabilities, number of units, and route settings, is determined. Following the design phase, estimates and specifications are prepared to confirm the desired automation requirements and implementation costs before proceeding with the delivery of the products.

Common Mistakes in AGV Implementation

Although AGVs offer numerous benefits, simply implementing them without proper planning may not yield the desired results. Two common cases of AGV implementation failures are as follows

Lack of Overall Design Expertise

The first case involves a lack of overall design expertise when implementing AGVs. This often occurs due to insufficient understanding of the site's characteristics, such as the size of the factory or warehouse, the types of transported goods, and the coordination with other transport equipment. Therefore, it is crucial to thoroughly understand the characteristics of the site and operations in advance.

Failure to Achieve Expected Benefits and Cost-Effectiveness

The second case involves not achieving the expected benefits and cost-effectiveness from AGV implementation. To achieve the desired results, it is essential to identify the major challenges that need to be addressed and thoroughly consider which type of AGV is suitable for resolving them. Additionally, it is necessary to evaluate the potential benefits from integrating with other equipment or services, as well as the support provided during updates.

To ensure successful AGV implementation, it is recommended to seek support from experienced professionals. In the next section, we will introduce ""LOGITO,"" a provider that offers total support for AGV implementation.

Total Support for AGV Implementation by LOGITO

LOGITO is a logistics automation solution provided by Daiichi Jitsugyo. Starting from on-site analysis, LOGITO offers comprehensive support