AGV Training

Lesson 1 • AGV Role in Facility Operations

Explains how AGVs integrate into warehouses, manufacturing lines, and distribution centres. Frames productivity, throughput, and labour impact as measurable outcomes.

Lesson 2 • AGV Types and Configurations

Surveys tow vehicles, unit load carriers, forklifts, and assembly line AGVs. Connects vehicle type to specific operational environments and payload capacity requirements.

Lesson 3 • What Is an AGV

Defines AGVs, their industrial purpose, and how they differ from manual and semi-automated vehicles. Establishes baseline vocabulary used throughout the course.

Lesson 1 • Selecting the Right Navigation Method

Provides a decision framework comparing cost, flexibility, accuracy, and infrastructure needs. Prepares learners to recommend guidance technology for real facility scenarios.

Lesson 2 • Vision and Inertial Guidance

Covers camera-based navigation and inertial measurement units as supplementary or primary guidance. Addresses use cases where laser or magnetic methods are impractical.

Lesson 3 • Natural Feature and SLAM Navigation

Introduces simultaneous localisation and mapping using environmental features without fixed infrastructure. Highlights flexibility advantages and computational requirements.

Lesson 4 • Magnetic Tape and Wire Guidance

Covers embedded wire and surface-mounted magnetic tape as fixed-path guidance methods. Explains installation requirements and path-change limitations relevant to facility planning.

Lesson 1 • Safety Regulatory Framework

Surveys international industrial vehicle safety standards and their functional requirements for AGVs. Establishes the compliance baseline transport operators and facility managers must meet.

Lesson 2 • Collision Avoidance Technologies

Examines laser scanners, ultrasonic sensors, and bumpers as layered collision prevention tools. Explains detection zones and how they are configured for different speed profiles.

Lesson 3 • Pedestrian and Traffic Management

Covers warning lights, audible alerts, floor markings, and traffic rules for mixed environments. Connects physical controls to behavioural safety culture in shared workspaces.

Lesson 4 • Safety Risk Assessment

Introduces hazard identification, risk scoring, and mitigation planning specific to AGV deployments. Produces a risk register as a practical deliverable for facility safety programmes.

Lesson 1 • Fleet Monitoring and KPI Dashboards

Introduces real-time dashboards, alert management, and performance reporting for AGV fleets. Builds the analytical skills needed to identify bottlenecks and optimise fleet performance.

Lesson 2 • Fleet Management Software Architecture

Explains server-client structure, communication protocols, and database functions in AGV fleet software. Provides the system literacy needed to configure and troubleshoot fleet operations.

Lesson 3 • System Integration with WMS and ERP

Covers API connections, data exchange formats, and synchronisation between AGV systems and enterprise software. Ensures learners can support integration projects with IT and operations teams.

Lesson 4 • Traffic Control and Deadlock Prevention

Explains zone blocking, segment reservation, and deadlock detection algorithms. Enables learners to design traffic rules that prevent gridlock in high-density AGV environments.

Lesson 1 • Route and Traffic Flow Design

Designs unidirectional and bidirectional AGV designated road or transit routes, passing zones, and intersection rules. Balances throughput efficiency with safety in high-traffic facility areas.

Lesson 2 • Fleet Sizing and Vehicle Selection

Applies throughput modelling and cycle time analysis to determine fleet size and vehicle type mix. Prevents over- or under-investment in AGV assets during project planning.

Lesson 3 • Commissioning and Go-Live Process

Covers map creation, route teaching, acceptance testing, and phased go-live procedures. Ensures a controlled transition from manual operations to full AGV deployment.

Lesson 4 • Facility Layout Analysis

Evaluates floor space, aisle widths, floor flatness, and load station positions for AGV compatibility. Identifies physical constraints that must be resolved before deployment begins.

Lesson 1 • Starting and Initialising an AGV

Walks through power-on sequence, navigation initialisation, and communication handshake with fleet software. Builds procedural accuracy for consistent and safe AGV startup.

Lesson 2 • Manual and Automatic Operating Modes

Compares manual joystick control with fully automatic mission execution and semi-automatic modes. Prepares transport operators to switch modes appropriately based on task and environment.

Lesson 3 • Pre-Operation Inspection Procedures

Details the systematic checks transport operators perform before each shift, including battery, sensors, and load handling. Establishes inspection habits that prevent operational failures.

Lesson 4 • Shutdown and End-of-Shift Procedures

Details safe shutdown sequences, parking position requirements, and battery charging initiation. Ensures vehicles are ready for the next shift and battery life is preserved.

Lesson 1 • Battery Maintenance and Management

Covers lead-acid and lithium battery care, charging cycles, and capacity testing procedures. Ensures transport operators maximise battery lifespan and avoid charge-related operational failures.

Lesson 2 • Preventive Maintenance Schedules

Establishes daily, weekly, and monthly maintenance tasks for mechanical, electrical, and software systems. Connects consistent maintenance to reduced unplanned downtime and extended vehicle life.

Lesson 3 • Sensor and Electronics Diagnostics

Introduces fault code reading, sensor calibration verification, and wiring harness inspection techniques. Enables technicians to isolate electronic faults efficiently using onboard diagnostics.

Lesson 4 • Mechanical System Inspection

Addresses drive wheel wear, gear lubrication, brake adjustment, and structural frame inspection. Builds the mechanical literacy needed to catch wear before it causes failures.

Lesson 1 • Energy Efficiency and Battery Strategy

Analyses energy consumption patterns and designs opportunity charging and fleet rotation strategies. Reduces energy costs and extends battery life across the entire fleet.

Lesson 2 • Strategic Fleet Expansion Planning

Develops business cases, ROI models, and phased expansion roadmaps for scaling AGV deployments. Aligns automation investment with long-term operational and financial objectives.

Lesson 3 • Continuous Improvement Frameworks

Applies lean and PDCA methodologies to AGV operations for sustained performance gains. Builds a structured improvement culture supported by regular review cycles.

Lesson 4 • Route and Schedule Optimisation

Applies simulation and algorithmic tools to refine AGV designated road or transit routes and task schedules for peak throughput. Validates optimisation changes through controlled testing before full deployment.