An Expert's Guide to Tugger AGV Systems & Automated Material Handling

In the evolving landscape of industrial automation, Automated Guided Vehicles (AGVs) specialized in towing operations are revolutionizing traditional material handling practices.

Ahead of our upcoming webinar hosted by BlueBotics, James Jones, Partner at MasterMover and our in-house automation expert, shares his expertise on the key considerations for businesses looking to purchase tugger and towing AGVs.

These sophisticated machines, known as tugger AGVs, represent a fundamental shift from conventional manual towing methods to intelligent, automated solutions. As manufacturing and logistics facilities face increasing pressure to improve efficiency while reducing operational costs, these autonomous towing systems have emerged as a transformative technology that not only automates repetitive transport tasks but also fundamentally reshapes how materials move through facilities.

Together with Bastian Solutions, FlexQube, and BlueBotics, we'll be discussing how towing AGVs are transforming industries, their operational capabilities, and the key factors to consider when integrating them into your business.

Sign up to join our webinar on January 23, 2025, and read on for James' expert automation insights.

AGV applications and benefits 

Towing or tugger AGVs are widely used to automate towing processes, making them particularly popular in the automotive and logistics industries. However, their applications extend far beyond these sectors. These AGVs are designed to pull carts in a train formation, making them ideal for environments where loads need to be moved over long distances with multiple drop-off and pickup points.

Manufacturing and heavy plant applications

In manufacturing, tugger AGVs handle repetitive tasks such as delivering components, parts, and equipment to production lines. In the automotive industry, they enable seamless sideline deliveries, supporting just-in-time production systems. Heavy plant assembly lines also benefit, as these vehicles can:

• Precisely transfer work-in-progress (WIP) and sub-assemblies through production stages.
• Reduce the need for manual handling, ensuring smoother processes.

Achieving the gold standard for Toyota

In one notable example, we recently collaborated with Toyota to implement towing AGVs to improve their operational efficiency and labor utilization in the movement of resin trunk lids at their factory in Europe. Previously, the driving process required a ride-on tow tractor and a licensed driver, necessitating dedicated resources for each shift. Identifying this as a non-value-adding activity and an area of waste, Toyota partnered with us to automate this process and maximize efficiency.

Distribution center & e-commerce logistics applications

The rapid growth of e-commerce has transformed the American distribution center landscape, with facilities now routinely exceeding 1 million square feet. In these vast spaces, the traditional reliance on manual forklifts for material movement creates significant operational bottlenecks and labor management challenges. Tugger AGVs are emerging as a game-changing solution, particularly for high-throughput operations where consistent, around-the-clock material movement is essential.

One significant example involves a third-party logistics provider that used our tugger AGVs to move rolling cages within a logistics depot. Previously, lift trucks were used to transport these cages across the site. However, forklifts could only move a limited number of cages at a time and often operated in congested areas. By implementing tugger AGVs, the company achieved:

• 5X as many cages transported in a single trip
• Improved operational efficiency by automating the movement of stock
• A reduction in the need for operators to transfer stock manually across the site

Businesses are increasingly turning to tugger AGVs to address inefficiencies in manual towing operations. Manual vehicles require dedicated operators for tasks that are often low-value yet essential. By automating these processes, companies can free up their workforce to focus on skilled and value-adding activities, resulting in significant productivity gains.

Tugger and towing AGVs are built to handle a diverse range of applications and loads. Our MasterTow AGVs support loads up to 44,000 lbs., with other models capable of towing up to 154,000 lbs. This flexibility allows them to cater to industries with varying needs, from automotive cart trains weighing around 4,400 lbs. to aerospace and heavy plant applications where loads exceed 22,000 lbs.

Load connection and navigation 

The way tugger AGVs hitch to their loads depends on the specific application. In our 25+ years of designing pedestrian and remote-controlled electric tuggers and tows, we've found this to be very much customer driven. Simple systems use manual connections, such as towing pins or ball hitches, while advanced operations employ auto-coupling mechanisms. Auto-coupling systems allow AGVs to autonomously hitch and unhitch carts without operator intervention, further streamlining processes.

Navigation technologies also vary. Many businesses prefer natural feature navigation, which uses existing environmental landmarks for guidance. This system is highly flexible, requires no physical infrastructure, and is easy to adapt. Alternatively, line-following navigation, which relies on a physical path installed on the floor, offers a more budget-friendly option but requires regular maintenance of the path.

Safety features, hybrid functionality, and outdoor capabilities 

Safety is a critical consideration, especially for towing AGVs handling large or complex loads and carts. Integrated safety scanners, adaptive safety fields, and emergency stop systems ensure safe operation even in congested areas. For example, in towing applications where multiple trailing carts follow the AGV, careful evaluation of the route and cart design is essential to maintain safety and stability.

Hybrid functionality, which allows AGVs to switch between automated and manual modes, is another important feature. This capability ensures operations remain fluid even if the AGV’s path is blocked or if maintenance is required. 

To ensure that towing AGVs can safely work alongside other traffic, a fleet management system will be installed to allow the AGV to communicate and interact with existing automated vehicles and infrastructure such as overhead doors and traffic light systems.

Our tugger AGVs can also operate outdoors, navigating slopes, rough terrain, and varying weather conditions. For example, we recently implemented an AGV system for a food and beverage bottling plant, where the vehicle navigated from an indoor facility through a busy distribution yard to an outdoor warehouse, seamlessly handling the transition between environments. 

Integrating AGVs

Integrating towing AGVs into existing workflows requires careful planning to ensure seamless operation. When replacing manual towing systems, it's crucial to account for factors such as load stability, route complexity, and site conditions.

To achieve a seamless and effective integration of AGVs, we recommend a phased approach. Instead of rolling out a fully autonomous system from the outset, businesses should start with simpler applications. For instance, an automated transfer system between a cart train and production equipment can be implemented first, with the AGV added later. This step-by-step strategy allows for process refinement and ensures the technology is well-suited to the specific application.

We prioritise close collaboration with customers during this phase, taking the time to truly understand their current needs and future goals. This tailored approach ensures that the chosen solution delivers maximum value and solves client challenges effectively. 

Maintenance and ongoing support 

Well-designed and correctly specified tugger AGVs will outperform manually driven vehicles and require minimal maintenance, but regular checks are essential to ensure optimal performance. Weekly maintenance tasks include cleaning scanner lenses and inspecting the AGV for debris. High-wear components, such as tires and drive wheels, should be checked quarterly. 

Telematics and data capture systems can enhance maintenance routines by providing real-time insights into motor temperature, battery performance, and other critical metrics. This enables preventative maintenance and helps identify potential issues before they escalate. 

We also provide comprehensive technical support and training to ensure the long-term success of AGV systems. From installation to ongoing remote and on-site support for the lifetime of the product, we pride ourselves on being the go-to AGV partner of choice. 

Investing in tugger AGVs 

The return on investment (ROI) for tugger AGVs is impressive, particularly for multi-shift operations.

For example, double-shift scenarios can achieve a 200% ROI over three years, while triple shifts see ROI figures as high as 649% over five years. These returns are driven by reduced labor costs, increased efficiency, and the ability to reallocate employees to more productive tasks versus traditional single operator and vehicle setups.

Tugger AGVs are reshaping the way businesses manage their towing processes, offering unparalleled benefits in efficiency, scalability, and cost-effectiveness. Whether you're in manufacturing, logistics, or any industry with repetitive towing tasks, these systems can transform your operations.

By working with industry experts with extensive experience in award-winning designs, safety features, and phased integration, companies can ensure a smooth transition to automation to truly maximize their ROI.

Register to attend the webinar to discover how our towing AGVs can support your business goals.