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AGV Fleet Size Calculator

Work out agv fleet size instantly with clear inputs, formula shown and shareable results.

About AGV Fleet Size Calculator

Fleet size is demand divided by the throughput of one vehicle, where that throughput is 60 divided by the cycle time in minutes, reduced by availability and inflated by congestion. Congestion is the term most often forgotten, and it grows non-linearly as the fleet fills the available routes.

Formula

AGV fleet

vehicle rate = 60 / (cycle x (1 + traffic loss)) x availability; fleet = ceil(demand / vehicle rate)

Worked example

With the default values below, AGV Fleet Size Calculator returns Vehicles required of 9. Change any input above and every figure here is recalculated in your browser.

Inputs used

Transport tasks per hour
60 tasks/h
Cycle time per task
6.5 min
Vehicle availability
85 %
Traffic and congestion loss
12 %

Results

Vehicles required
9 vehicles
Theoretical requirement
8.57 vehicles
Tasks per vehicle per hour
7.01 tasks/h
Utilisation of the chosen fleet
95.2% %

Step by step

  1. 1Values used
  2. 2AGV fleet
  3. 3Vehicles required= 9 vehicles
  4. 4Theoretical requirement= 8.57 vehicles
  5. 5Tasks per vehicle per hour= 7.01 tasks/h
  6. 6Utilisation of the chosen fleet= 95.2 %

Assumptions and limits

  • The result is derived only from the 4 inputs listed above. Anything not among them is not part of the calculation.
  • In particular, this calculator does not take inflation, tax, fees or charges or compounding frequency into account.
  • Figures are rounded for display to 2 decimal places, so totals built from several rounded parts can differ slightly from the unrounded arithmetic.

How these calculators are built and tested is described on the Methodology page. If a figure looks wrong, please report it.

Frequently Asked Questions

Why does congestion grow non-linearly?

Vehicles block each other at intersections and single-lane sections, so waiting time rises sharply once route utilisation passes roughly 60%.

Should I round up or add a spare?

Round up, then consider one additional vehicle for maintenance cover if the process cannot tolerate reduced throughput.

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AGV Fleet Size Calculator – Calculate Vehicles required