AMR, AGV & Intralogistics Automation worked example

Internal Logistics Labor Savings Calculator at 17% supervision and exception allowance: a worked example

What does the result look like when supervision and exception allowance reaches 17%? The full calculation is worked below with real intermediate numbers. an operations manager needs to estimate labor hours displaced or reassigned by an intralogistics automation scenario

The inputs for this scenario

  • Moves shifted from manual handling: 9,500 moves (unchanged)
  • Current manual handling rate: 3.8 moves/min (unchanged)
  • Supervision and exception allowance: 17 % (raised for this scenario; the documented default is 15)

Working through the calculation

  • Applying the documented formula (Base manual handling hours = moves shifted from manual handling รท current manual handling rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,925 hr for recovered logistics labor hours, the number this scenario is built around.
  • At this operating point the engine returns 2,500 hr for base manual handling hours.
  • At this operating point the engine returns 17 % for residual supervision and exception allowance.
  • At this operating point the engine returns 3.8 moves/min for current manual handling rate.

How this compares with the baseline

  • Against the tool's baseline example, where supervision and exception allowance sits at 15% and the headline result is 2,875 hr, this scenario comes in 1.74% above the baseline at 2,925 hr.
  • A figure at this level is achievable when supervision and exception allowance is genuinely sustained, not just peaked for a shift. It assumes a steady manual handling rate; the allowance covers residual oversight but not new tasks like cart staging or fleet babysitting that can erode the savings if poorly designed.

Results at a glance

  • Recovered logistics labor hours: 2,925 hr (headline result)
  • Base manual handling hours: 2,500 hr
  • Residual supervision and exception allowance: 17 %
  • Current manual handling rate: 3.8 moves/min

Run it with your numbers

  • Every input above is editable in the live Internal Logistics Labor Savings Calculator calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.