WAREHOUSE DATA PREPARATION
Automated putaway and retrieval depend on more than a warehouse map. Product, pallet and load records must accurately describe the physical goods so that the warehouse system can assign suitable locations and the AGV forklift can handle each load within its operating limits.
Warehouse automation projects can encounter avoidable delays when the digital inventory record does not match the physical pallet. A product may be recorded under the correct SKU but arrive on an unexpected pallet type. A load may exceed its planned height, have an unusual center of gravity or include overhanging cartons that affect clearance.
These differences can influence storage eligibility, fork entry, lifting, route clearance and the choice of destination. They can also create repeated manual checks if the system lacks the information required to distinguish standard loads from special handling cases.
Before deploying AGV forklifts, review the master data that describes products, handling units and load restrictions. The objective is to make the warehouse's digital rules consistent with the goods the vehicles will actually encounter.
A stock-keeping unit (SKU) describes a product or inventory item. A handling unit describes the physical unit moved through the warehouse, such as a pallet containing one or more SKUs.
The distinction matters because the same SKU may arrive in different quantities, pallet configurations or packaging formats. Conversely, one pallet may contain several SKUs if mixed-pallet handling is permitted.
Define which data belongs to the product record and which belongs to the physical handling unit. The product record may describe product dimensions, storage restrictions and handling requirements. The handling-unit record should identify the actual pallet or load and capture the attributes needed for the current movement.
Do not assume that the nominal dimensions of a product describe the complete loaded pallet. The vehicle must handle the actual unit, including its pallet base, packaging, wrapping and any permitted overhang.
For each approved load category, determine which attributes are required for safe handling and storage assignment.
Load weight: total loaded weight where it is available and relevant to vehicle and storage limits.
Overall dimensions: actual loaded length, width and height, including packaging and overhang.
Pallet type: pallet footprint, fork-entry direction and relevant underside geometry.
Load stability: approved packaging and stacking conditions for automated handling.
Handling restrictions: fragile goods, special orientation or other documented constraints.
Storage eligibility: restrictions related to location type, load height, weight or inventory status.
Not every warehouse needs every field for every SKU. Work with the AGV supplier and warehouse process owner to identify which attributes are necessary for the planned vehicle configuration and storage rules.
Where a value is unknown, do not automatically replace it with an assumed standard. Decide whether the load can be handled under a verified default rule, requires measurement or must be routed through an inspection process.
Master data should be checked against representative pallets before the system is configured. Start with frequently handled SKUs, loads with the largest dimensions or weight, and products with unusual packaging or handling requirements.
Compare the stored values with actual measurements. Check whether the record describes the product alone, the pallet alone or the complete loaded unit. These definitions must be consistent across the warehouse and fleet systems.
Pay particular attention to mixed pallets and variable loads. If the contents and overall dimensions change from one handling unit to another, a single SKU-level value may not describe every physical load accurately.
Record the source of each critical attribute and define who is responsible for correcting discrepancies. Depending on the process, the authoritative value may come from the product record, packaging specification, receiving measurement or another approved source.
Automated storage assignment should consider whether a load is suitable for the proposed destination. A location may have enough nominal floor area but still be unsuitable because of height restrictions, load limits, access geometry or inventory rules.
Define the rules that connect load attributes to eligible storage locations. These may include maximum permitted load dimensions, location capacity, pallet type, inventory status and special handling restrictions.
For high-bay warehouses, confirm the actual height and clearance requirements of each relevant storage position. The load envelope must be considered alongside the rack configuration and the operating limits of the selected forklift.
Where the warehouse uses multiple pallet standards, identify which locations and vehicle configurations support each type. Avoid relying on a single default pallet assumption when the incoming inventory includes several formats.
Missing data is an operational condition that needs a defined response. If a pallet arrives without a valid identifier or with dimensions outside the approved range, the system should not quietly assign it to a normal storage location.
Establish rules for incomplete records, duplicate handling-unit identifiers, conflicting weight values and unexpected pallet types. Depending on the warehouse process, a load may require verification, a designated inspection position or authorized manual review.
Ensure that correcting a record does not accidentally create a duplicate handling unit or break the link between the physical pallet and its inventory transaction.
Where data is updated after receiving, define how the revised attributes become available to the warehouse management and fleet control systems. Confirm that pending tasks use valid information rather than an outdated record.
Master-data validation should be tested through the warehouse workflow, not only by checking whether required database fields are populated.
Create a transport task for a standard approved pallet.
Test a load with dimensions near the permitted limit.
Submit a load with a missing or unknown identifier.
Check how the system handles an unexpected pallet type.
Verify that storage assignment respects the load and location restrictions.
Confirm that inventory records remain consistent after a failed or corrected task.
Review the results with warehouse operations, IT and the AGV supplier. A technically valid record is not sufficient if the physical load cannot be handled as expected.
Product records and physical handling-unit records are clearly distinguished.
Required load dimensions, weight and pallet attributes are defined.
Representative physical loads have been measured and checked.
Storage eligibility rules reflect actual load and location limits.
Missing, duplicate and conflicting data have defined responses.
Data ownership and correction responsibilities are documented.
End-to-end tests confirm that the system uses the correct attributes.
Key checkpoint: The data used to assign a destination must describe the actual handling unit closely enough for the warehouse's approved storage and vehicle rules. Do not assume a product-level record always describes the complete pallet.
Before requesting a final system configuration, prepare a representative data sample containing common SKUs, handling-unit examples, dimensions, weights, pallet types and storage restrictions. Mark any values that remain unverified.
Ask the supplier which attributes are needed for task assignment, vehicle handling, storage eligibility and system integration. Agree on the data format, update process and treatment of incomplete records before commissioning begins.
📖 AGV Forklift Guide — Essential manual for selection and safety.
⚙️ How AGV Systems Work — A deep dive into navigation and logic.
⚖️ AGV vs. AMR Comparison — Choosing the right technology for your facility.
💰 AGV Cost and ROI — Evaluating investment and payback periods.
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