Warehouses rarely keep exactly the same product mix for years. New SKUs may be introduced, packaging can change, and product dimensions or pallet configurations may vary.
When a warehouse already operates automated forklifts, the important question is whether these changes can be handled through configuration and process updates or whether the AGV fleet itself requires modification.
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A SKU is not only an inventory record. Its physical characteristics can affect automated handling.
Important factors include:
Product dimensions
Product weight
Pallet dimensions
Load distribution
Load center
Packaging stability
Stacking height
Label location
Required storage position
A new SKU may therefore fit the warehouse's existing WMS process but still require validation for automated handling.
No.
If the new product uses the same pallet type, load range, dimensions, identification method, and storage rules already supported by the fleet, the change may primarily involve WMS and warehouse configuration.
However, a new SKU can require additional engineering if it changes the physical handling requirements.
Before adding a new SKU to an automated warehouse, compare its physical characteristics with the existing operating envelope.
Maximum gross weight
Minimum and maximum pallet dimensions
Load center
Overall height
Fork entry requirements
Packaging stability
Storage location requirements
The supplier should confirm whether the new configuration falls within the AGV's approved operating range.
A new SKU may require a different storage position because of its dimensions or handling requirements.
For example, a taller pallet may require a different rack level, while a heavier pallet may need a position with suitable load capacity.
Therefore, SKU onboarding should be coordinated between WMS rules, rack configuration, and AGV handling capabilities.
New SKUs may also introduce new barcode formats, label positions, or identification rules.
If the AGV relies on barcode or other identification information, verify:
Label readability
Label location
Barcode format
Scanner position
WMS master-data mapping
A product can be correctly registered in the WMS and still create problems if its physical identification cannot be reliably detected.
Do not introduce a new physical SKU directly into the full production flow without validation.
A controlled test can include:
Register the SKU in the WMS test environment.
Confirm pallet and load information.
Verify AGV handling compatibility.
Test pallet pickup.
Test transport.
Test rack placement.
Test retrieval.
Verify inventory updates.
Several solutions may be possible depending on the change.
Change the pallet configuration
Use a different storage location
Modify task rules
Add suitable attachments
Change identification equipment
Modify vehicle configuration
Use manual handling for the exception SKU
The correct solution should be determined from the actual handling requirement rather than assuming that a new AGV is necessary.
AGV automation depends on accurate master data.
Important fields may include:
SKU code
Product dimensions
Gross weight
Pallet type
Storage restrictions
Handling class
Identification information
The exact data structure depends on the WMS and automation architecture.
Supported pallet dimensions
Load range
Load center range
Fork dimensions
Maximum handling height
Identification requirements
Software configuration options
Whether new SKU data requires engineering changes
A clear SKU onboarding process allows a warehouse to introduce new products without unnecessarily disrupting the existing AGV fleet.
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