AMR, AGV & Intralogistics Automation worked example

Tugger Route Capacity Calculator at 66% tugger route uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop tugger route uptime to 66%, then walk the calculation through step by step. Calculate tugger train delivery capacity from carts per loop, route loops per shift, tugger uptime, and usable delivery rate.

The inputs for this scenario

  • Carts or loads delivered per loop: 8 loads/loop (held at the documented default)
  • Available tugger route loops: 34 loops/shift (held at the documented default)
  • Tugger route uptime: 66 % (the input this scenario stresses; the baseline uses 92)
  • Usable delivery completion rate: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross route delivery capacity = carts or loads per loop × available tugger route loops.
  • Usable tugger route capacity works out to 174 loads/shift at these inputs, and this is the headline figure for the scenario.
  • Gross route delivery capacity works out to 272 loads/shift at these inputs.
  • Moves lost to downtime works out to 92.48 loads/shift at these inputs.
  • Loads lost to missed stops or exceptions works out to 5.39 loads/shift at these inputs.

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 28.26% below the baseline at 174 loads/shift.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to tugger route uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes loads per loop and loop count are steady; uneven cart fill, variable demand by stop, or kitting at the supermarket can make real throughput swing well below the average.

Results at a glance

  • Usable tugger route capacity: 174 loads/shift (headline result)
  • Gross route delivery capacity: 272 loads/shift
  • Moves lost to downtime: 92.48 loads/shift
  • Loads lost to missed stops or exceptions: 5.39 loads/shift

Run it with your numbers

  • To rerun this with your own numbers, open the live Tugger Route Capacity Calculator calculator, set tugger route uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.