AMR, AGV & Intralogistics Automation worked example

Tugger Route Capacity Calculator at 99% tugger route uptime: a worked example

Push tugger route uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a material flow planner needs to confirm whether a tugger loop can support line-side delivery demand

The inputs for this scenario

  • Carts or loads delivered per loop: 8 loads/loop (unchanged)
  • Available tugger route loops: 34 loops/shift (unchanged)
  • Tugger route uptime: 99 % (raised for this scenario; the documented default is 92)
  • Usable delivery completion rate: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross route delivery capacity = carts or loads per loop × available tugger route loops) to the inputs above produces each figure below.
  • At this operating point the engine returns 261 loads/shift for usable tugger route capacity, the number this scenario is built around.
  • At this operating point the engine returns 272 loads/shift for gross route delivery capacity.
  • At this operating point the engine returns 2.72 loads/shift for moves lost to downtime.
  • At this operating point the engine returns 8.08 loads/shift for loads lost to missed stops or exceptions.

How this compares with the baseline

  • Against the tool's baseline example, where tugger route uptime sits at 92% and the headline result is 243 loads/shift, this scenario comes in 7.61% above the baseline at 261 loads/shift.
  • It computes the usable loads a tugger milk run can deliver per shift by derating gross loop capacity for route uptime and delivery completion rate. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Usable tugger route capacity: 261 loads/shift (headline result)
  • Gross route delivery capacity: 272 loads/shift
  • Moves lost to downtime: 2.72 loads/shift
  • Loads lost to missed stops or exceptions: 8.08 loads/shift

Run it with your numbers

  • Every input above is editable in the live Tugger Route Capacity Calculator calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.