How to Implement an AGV System in Your Existing Facility: A Step-by-Step Guide

Many European manufacturers and logistics operators assume that implementing an AGV requires a facility specifically designed for it — new floors, a new warehouse layout, or a greenfield project. The reality is different. With careful planning, the Tuskrobots APR can be integrated into your existing operations with significantly less effort than most teams expect.

This guide walks you through the practical steps of implementing an AGV system — specifically the APR — in a facility that is already in operation. Whether you run a busy distribution centre, a production hall, or a multi-site intralogistics operation, this process can be applied to your situation.

Why Existing Facilities Are Suitable for AGV Integration

The assumption that AGV technology requires a complete redesign of the facility is outdated. Modern AGVs such as the APR are designed for flexibility — they work alongside existing racking systems, conveyor technology, and manual processes. European industry has been demonstrating this for years: manufacturers in Germany, the Netherlands, Belgium, and Scandinavia are successfully deploying AGVs in facilities that have already been in operation for decades.

What matters is a structured approach: analyse, plan, pilot, integrate, and scale. Skipping or rushing individual phases is one of the most common reasons why implementations fall short of expectations.

Step 1: Analyse Your Facility and Material Flow

Before equipment is ordered or installed, you should carry out a thorough analysis of your current operations.

Map Existing Logistics Routes

Start by documenting every material flow in your facility — from goods receipt to storage, from storage to production lines, and from production to dispatch. Identify material flows that are:

• frequent and recurring
• predictable in terms of route and load type
• currently handled by manual labour or forklifts

These processes are the best candidates for AGV automation with the APR.

Identify Bottlenecks Suitable for AGV Automation

Look for areas where delays occur regularly: waiting times at picking stations, queues at loading docks, or uneven throughput between production steps. AGVs are particularly effective at reducing such bottlenecks by ensuring constant, fatigue-free transport between fixed points.

It is equally important to understand where not to start: complex picking areas with many different SKUs, areas with highly variable traffic volumes, or zones that would require major structural changes to deploy an AGV. A good implementation plan starts with quick wins.

Step 2: Define Your AGV Use Cases and Objectives

Once you have a clear picture of your material flows, define what success should look like in practical terms. This means setting clear objectives before implementation:

• Throughput target: How many transport cycles per hour need to be replaced or supplemented?
• Labour reallocation: Which manual tasks will be replaced, and where will these employees be deployed afterwards?
• Operating hours: Will the APR be used during shifts, around the clock, or only during peak times?
• Integration scope: Will the AGV operate as a standalone unit or be fully integrated into your WMS or ERP?

Defining these objectives early prevents scope creep and ensures that the implementation delivers measurable ROI from day one.

Step 3: Check the Infrastructure Requirements

The APR is designed for use in standard industrial environments above 0 °C, covering the vast majority of European production and distribution facilities. Nevertheless, a basic infrastructure check before implementation is essential.

Floor Condition and Surface Requirements

AGVs require smooth and level floors to operate reliably. Check your facility for:

• cracks, raised joints, or uneven surfaces along travel routes
• drainage channels or threshold plates that could obstruct movement
• floor coatings that may affect traction

In most cases, minor floor repairs — rather than a complete floor renewal — are sufficient. Your Tuskrobots implementation team will identify critical areas during the site analysis.

Wi-Fi and Connectivity Planning

The APR relies on a stable wireless network for fleet management, route updates, and communication with the WMS. Carry out an on-site Wi-Fi analysis early to identify dead zones or areas with interference. In some facilities, a small number of additional access points may be required — this is usually a low-cost measure with minimal impact on operations.

Step 4: Run a Pilot Project Before the Full Rollout

A phased implementation — starting with a pilot project — is strongly recommended for any AGV deployment in an existing facility. A pilot project typically includes:

• deploying one or two APR units on a defined route
• operating the AGV alongside existing processes for a defined period, typically four to eight weeks
• measuring performance against the objectives defined in Step 2
• identifying necessary adjustments before scaling

Most of the learning process takes place during the pilot phase. It reveals unexpected interactions with other equipment, highlights Wi-Fi gaps, and gives your team the opportunity to build confidence in the technology before it becomes business-critical.

European operations that have followed this approach regularly report faster full rollouts, fewer post-implementation issues, and stronger internal acceptance among shop-floor teams.

Step 5: Integrate the AGV into Your WMS or ERP

One of the key advantages of the APR is its ability to connect directly with your existing Warehouse Management System (WMS) or Enterprise Resource Planning (ERP) platform. This turns the AGV from a standalone transport device into an integrated part of your digital supply chain.

Key integration points include:

• Order assignment: The WMS sends transport orders directly to the APR fleet, eliminating the need for manual task allocation
• Inventory tracking: Every AGV movement is logged and visible in real time within your WMS
• Exception handling: If the AGV cannot complete a task, for example due to a blocked route or a load-related issue, the exception is automatically reported in the WMS

Tuskrobots supports standardised integration protocols, making it compatible with leading WMS and ERP platforms used across European industry. For facilities that do not yet have a WMS in place, Tuskrobots can advise on lean solutions that work well alongside an APR implementation.

Step 6: Train Your Team and Support the Change

Technology is only one half of any AGV implementation. The human side — how your team adapts to working with autonomous vehicles — is equally important.

Training for an APR implementation typically includes:

• Safety protocols: safe interaction with moving AGVs, emergency stop procedures, and zone management
• System monitoring: how operators and supervisors monitor AGV status, manage exceptions, and generate reports
• Basic troubleshooting: how common operational issues can be resolved without having to request specialised support

It is also worth investing in change management. Employees who understand why the AGV is being introduced — and who see that their roles are evolving rather than disappearing — are much more open to the technology. In most European implementations, AGVs primarily take over the most physically demanding and repetitive tasks, creating space for higher-value work.

Step 7: Scale and Continuously Optimise

Once your pilot project has been successfully completed and your team is confident working with the APR, scaling is straightforward. Additional units can be gradually added to the fleet to cover new routes or additional shifts as your automation goals grow.

Continuous optimisation maximises long-term ROI:

• Route optimisation: adapting AGV routes as your facility layout or processes change
• Fleet planning: fine-tuning when and how many units are active depending on demand patterns
• Data-driven decisions: using AGV operating data — transport cycles, idle times, and exception rates — to identify further automation opportunities

The APR is designed to grow with your operation. European manufacturers that start with a single-unit pilot often expand to multi-unit fleets within 12 to 18 months — supported by performance data from the initial implementation.

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