AGV PROJECT PLANNING
A practical site survey checklist for warehouse teams evaluating autonomous forklifts. Organize layout data, load specifications, traffic conditions, and operating requirements before supplier selection.
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An AGV forklift quotation is only as reliable as the information behind it. A warehouse may appear straightforward during a walk-through, but rack clearances, pallet variations, floor transitions, traffic conflicts, and delivery priorities can materially change the proposed system.
Before asking suppliers to recommend equipment, prepare a consistent site survey package. It allows different proposals to be evaluated against the same operating conditions instead of comparing prices based on different assumptions.
Start with a current CAD drawing or a dimensioned floor plan. The drawing should show more than the building outline. Include rack rows, aisle widths, columns, doors, fire exits, loading areas, elevators, ramps, and existing equipment.
Mark every proposed pickup and drop-off location.
Identify one-way aisles, restricted areas, and pedestrian crossings.
Record aisle width at the narrowest points, not only at the entrance.
Show floor joints, slopes, thresholds, and other transitions.
Identify areas where temporary storage or staging regularly blocks access.
If CAD drawings are unavailable, use a measured floor plan with clear dimensions. Photographs and short videos can supplement the drawing, but they should not replace measurements where clearances determine whether a truck can operate.
Nominal pallet size and maximum load weight are not enough to specify an AGV forklift. Suppliers need to understand the load's physical dimensions, center of gravity, stability, and condition during normal operation.
Maximum, typical, and minimum load weights.
Pallet length, width, height, and fork-entry direction.
Load overhang, uneven weight distribution, and unstable packaging.
Whether pallets are wooden, plastic, metal, or a mixed type.
Whether empty pallets, damaged pallets, or wrapped loads are included.
Where several pallet types are used, provide photographs and measurements for each type. A solution that handles one standard pallet reliably may need additional testing or a different handling arrangement for other load formats.
List the movements the AGV forklift is expected to perform. For each movement, record the origin, destination, load type, frequency, and any required confirmation before the next step.
For example, receiving may require moving pallets from an inbound staging area to a buffer location. Putaway may require transport from a buffer to a rack location. Replenishment may involve moving pallets from reserve storage to a picking area. These flows have different travel distances, traffic patterns, and delivery priorities.
Use actual operating data where possible. Record trips per hour or shift, peak periods, average transport distance, and how demand changes during the day. A daily total alone may hide a short peak that determines the required fleet capacity.
Record conditions that may affect navigation, safety, or equipment operation. These include lighting changes, reflective surfaces, dust, temperature, outdoor exposure, floor quality, and shared traffic with people or manual forklifts.
Also document the site's operating schedule, cleaning windows, maintenance access, emergency procedures, and any periods when routes must remain clear. Do not assume that a route is continuously available simply because it appears open during a survey.
Send each supplier the same core information. This makes proposals easier to compare and helps reveal which assumptions still require validation.
01 — Dimensioned warehouse layout
02 — Pallet and load specification sheet
03 — Origin-destination movement list
04 — Traffic, access, and safety constraints
05 — Shift schedule and peak demand data
06 — Existing WMS/WCS interfaces and operating rules
07 — Photos of critical aisles, rack interfaces, and handover points
A useful proposal should clearly distinguish confirmed information from assumptions. Ask which aisle dimensions require on-site measurement, which pallet types need testing, how pickup and drop-off positions will be validated, and what information is still needed to estimate throughput.
Request that exclusions, site modifications, interface responsibilities, and acceptance conditions be documented. This prevents unresolved site conditions from becoming unexpected changes after equipment delivery.
Before finalizing the quotation, verify that the layout, loads, routes, peak demand, and handover points describe the same operating scenario. Missing data should be listed explicitly rather than silently replaced with optimistic assumptions.
Preparing a site survey package gives warehouse operators a clearer basis for comparing AGV forklift models, estimating project scope, and identifying technical risks early. ZCNest can review warehouse movement requirements, load specifications, and layout constraints to support model selection and project planning.
📖 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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