If you're still using manual transport systems in your facility, you're likely feeling the squeeze: delays, inefficiencies, and mounting labor costs. As production grows more complex, these pain points only intensify. At Eleven Dynamics, we help manufacturers shift from manual handling to fully autonomous transport solutions seamlessly. This guide walks you through what that transformation looks like, step by step.
Manual transport has served its purpose in many facilities, but it's now becoming a clear source of inefficiency. Idle operator time, inconsistent deliveries, and rising labor expenses are just a few of the challenges. Common issues like empty return trips and delayed replenishments can cause bigger disruptions than they used to, especially in multi-shift environments where consistency and uptime are crucial. Switching to AGVs helps eliminate these gaps. Transport becomes more reliable, traceable, and accurate, improving the overall performance of your logistics process.
Understanding the difference between AGVs and AMRs is key to selecting the right system. AGVs (Automated Guided Vehicles) follow predetermined paths, either through physical guides like magnetic tape or virtual ones. They work well for repeatable, high-volume tasks, such as those in automotive production or fixed-route bin movements.
AMRs (Autonomous Mobile Robots), on the other hand, navigate freely using real-time mapping and sensors. They're better suited for dynamic environments and more complex routing tasks. At Eleven Dynamics, we use advanced platforms that go a step further by combining mobile robots with 3D metrology tools. This allows for automated quality checks while transporting goods, something traditional AGVs cannot achieve.
Before any technology comes into play, it's important to fully understand your existing material flow. Do you follow a FIFO (first-in, first-out) logic? Or are tasks prioritized based on location, readiness, or energy efficiency?
Once that’s clear, logistical rules can be defined. For example, if a robot is already carrying material, it needs to complete that job before taking on another, even if another task appears closer. This type of rule-based task management is essential for creating an efficient and predictable system. A well-documented layout of zones, machines, and workflows sets the stage for smart routing.
Safety regulations are non-negotiable when it comes to deploying autonomous systems in industrial settings. Within the EU, standards such as ISO 3691-4 and ISO 13849-1 specify how these systems must be designed. CE certification and compliance with the Machinery Directive 2006/42/EC are also required.
That means your system must include certified components like safety-rated LiDARs, redundant brakes, and defined speed zones. Safety isn’t something you can add later: it has to be engineered and validated from the start, following protocols like ISO 12100.
The physical setup depends on the type of system you choose. Line-following AGVs require magnetic tape or optical paths installed on the floor. SLAM-based AMRs are more flexible and need far less preparation, though clear lighting and visible markers still help.
Regardless of the navigation method, a strong facility-wide Wi-Fi network is essential. You’ll also need to plan for charging stations, marked safety zones, and route clearance to ensure smooth operations.
For most companies, the return on investment for AGV systems is reached within 18 to 36 months. Factors like shift patterns, transport volume, and system complexity influence the timeline.
It’s important to consider the full cost of ownership, including vehicle hardware, fleet software, integration services, commissioning, charging infrastructure, and support. But beyond cost savings, many companies find additional value in improved safety, easier scaling, and better data transparency, benefits that make the investment worthwhile even in smaller-scale operations.
Transitioning to an autonomous system works best when done gradually. Start with a proof-of-concept to test your routes, behavior, and integration with existing systems. Then, launch a small pilot fleet in a specific area.
As performance improves and confidence grows, you can expand into more zones. Keep manual transport running in parallel until the new system is fully validated. With good training and clear change management, the shift becomes smooth and sustainable.
Upgrading from manual to autonomous transport is more than a technical improvement. It’s a strategic step toward more efficient, scalable, and intelligent operations. With a clear roadmap and the right partner, this transformation becomes not just achievable, but a competitive advantage.
