Process tool

AGV throughput calculator for the process

Enter route parameters to quickly estimate the AGV fleet required for the whole process.

The calculator updates live, sums multiple routes and shows the recommended fleet for the entire process.

AGV calculator

Quickly estimate AGV fleet size for the process

Enter route parameters to see the recommended fleet size and key process indicators.

Route

Routes to calculate

Add a separate route whenever the AGV serves a different pickup or drop-off point.

Route 1 Route name

Route working time How many hours this route must be served.

Transport volume in working time How many transports this route has to complete in that time.

transports

One-way route distance Distance from pickup point to drop-off point.

Pallet handling steps per cycle Example: pickup + drop-off = 2 handling steps.

ops

Route result

Cycle distance 220 m

Travel time 183.3 s

Charging allowance 55 s

Cycle time 6.57 min

1 AGV throughput 9.14 trips/h

Fleet need per route 1.79 AGV

Process summary Sample data

You are looking at a sample route. Change the values to calculate your own process.

Fleet recommendation

Sample result

2 AGV

This result is based on the sample starting configuration.

Exact result 1.79 AGV

Total transport volume 131 transports

Average 1 AGV throughput 9.14 trips/h

Most demanding route Production -> Buffer (1.79 AGV)

Longest cycle 6.57 min

Change the values or add routes to calculate your own case.

How to read the result

Exact result shows the summed demand, for example 1.83 AGV.
Recommended fleet rounds the result up to whole vehicles.
If the process contains several independent routes, add them separately and calculate them together.

Want to validate the result?

We can review the real routes, process constraints and help size the target AGV fleet.

Book a consultation

How to read the result

What to validate after the first calculation

Treat the calculator output as a fast estimate of fleet demand for the route mix you entered. The most useful step is to compare several scenarios for the same process and see how route length, transport volume and pallet manipulations change the result.

If the outcome is close to the threshold of one additional AGV, review peak-load assumptions, delays at pick-up or drop-off points and traffic organization, because those details often determine the final fleet size.

Calculate the baseline

Start with the real parameters of the current process to understand the minimum fleet needed for the existing operating model.

Compare scenarios

Then adjust distance, transport count or pallet operations to identify which variable puts the biggest pressure on fleet demand.

Validate on site

Finally, compare the result with traffic constraints, station availability and charging logic before freezing the final fleet architecture.