How do you calculate how many AMRs you need?

Vehicles = loads / (available minutes / cycle time x loads per trip x mission success), rounded up. With 240 loads a shift, 2 loads per 12-minute trip, 480 scheduled minutes, 88% availability and 96% success, each vehicle has 422.4 minutes and moves 67.6 loads, so 240 loads need 3.55 vehicles: 4, the AGV Fleet Size calculator's own example. For several routes the workbook adds every route's vehicle minutes first.

What cycle time should I use for a route?

One complete trip: pick-up, loaded travel, drop-off, any waiting at the stations and the empty return or reposition before the next mission. Time real trips or take them from the supplier's route study. Leave charging out of the cycle time if it is already in the availability figure, so it is not counted twice.

Why plan the fleet below 100% utilisation?

At 100% every vehicle is busy all the time it is available, so any traffic, queue at a station or burst of demand makes loads late. The planning limit on Setup is your choice; at 100% the workbook matches the calculator's sizing. In the example the routes need 8 vehicles at 100% and 9 at an 85% limit.

Shared fleet or dedicated vehicles per route?

A shared fleet pools the fractions: a route that needs 1.4 vehicles and one that needs 0.6 share two vehicles, while dedicated vehicles would need three. In the example the shared plan needs 9 vehicles against 11 if every route had its own. Dedicated vehicles still make sense where routes need different vehicle types or a fixed delivery rhythm.

Does the template size chargers or check traffic?

No. Charging time belongs in the availability figure, and chargers are sized with the Charging Station Count calculator. Congestion, shared lifts and doors, and dispatch rules can need more vehicles than the averages show, so confirm the fleet with the supplier's simulation.

Does the workbook use macros?

No. It is a plain .xlsx with ordinary formulas, tables and native charts, so it opens without enabling macros. The Verify sheet re-checks the formulas against fixed test cases and shows Self-check: PASS.

Packaging and Warehouse

AMR Fleet Sizing Excel Template

AMRs needed = the vehicle minutes every route takes ÷ the minutes one vehicle is available, rounded up. List your routes with their loads, trip size and cycle time, and see the planned, minimum and peak-hour fleet, each route's share of the work and the fleet as demand grows.

Free, and a plain .xlsx with no macros to enable. A CSV with live formulas and a printed how-to guide come with it.

Overview

This AMR fleet sizing template is a working Excel workbook for industrial engineers, intralogistics and automation project leads, and plant managers comparing autonomous mobile robot or AGV quotes. Each route or mission type is one row with its loads per shift, the loads one vehicle carries per trip and the cycle time of one complete trip. It ships with eight routes of a fictional dishwasher plant, from receiving to shipping, so every tile and chart is filled in when you open it.

Trips per shift are the loads divided by the loads per trip and by the mission success rate, because failed missions are run again, and vehicle minutes are the trips times the cycle time. One vehicle is available for its scheduled minutes times the fleet availability: 450 x 88% = 396 minutes in the example. The eight routes take 2,889 vehicle minutes, so the minimum shared fleet is 2,889 / 396 = 7.3, rounded up to 8, the same arithmetic as the AGV Fleet Size calculator. At an 85% planning limit the planned fleet is 9, the busiest hour at 1.3 times the average needs 10, and giving every route its own vehicles would take 11.

In the example, receiving and the two stores routes take 59% of the vehicle time, sharing one fleet saves two vehicles against dedicated routes, and the peak hour needs one more vehicle than the plan, so either plan for 10 or flatten the peak. At 120% of today's loads the planned fleet rises to 11. The download is a plain .xlsx with no macros. A CSV with live formulas is also included for other tools; the fleet sizes, charts and self-check are in the .xlsx.

What this template includes

Routes table, one row per route or mission type: loads per shift, loads carried per trip and the cycle time of one complete trip
Per route: trips per shift with failed missions run again, vehicle minutes, vehicles of work, dedicated vehicles and share of the fleet's work, with a Check column
The fleet sized four ways: minimum shared fleet, planned fleet at your utilisation limit, peak-hour fleet and dedicated-route fleet, plus the planned fleet's utilisation
Dashboard with four tiles, a chart of vehicles of work by route and a chart of the fleet as demand grows from 80% to 150% of today's loads
Method sheet with every formula, and a Verify sheet that re-checks the formulas against an independent reference and the AGV Fleet Size calculator (Self-check: PASS)
CSV with live formulas for the Routes table; the fleet sizes, charts and self-check are in the .xlsx

Suggested use case

Use it before asking for AMR or AGV quotes, to check a supplier's proposed fleet against your own routes, or to see how many more vehicles a new line or a busier peak hour needs.

How to use it

On Setup, type the site name, the minutes each vehicle is scheduled per shift, fleet availability, mission success rate, your planning utilisation limit and the peak-hour factor.
On Routes, add one row per route or mission type with its loads per shift, the loads one vehicle carries per trip and the measured cycle time of one complete trip.
Fix anything the Check column names.
Open the Dashboard: read the planned and peak-hour fleets, see which routes take the most vehicle time, and check the fleet at higher demand.

Frequently Asked Questions

How do you calculate how many AMRs you need?: Vehicles = loads / (available minutes / cycle time x loads per trip x mission success), rounded up. With 240 loads a shift, 2 loads per 12-minute trip, 480 scheduled minutes, 88% availability and 96% success, each vehicle has 422.4 minutes and moves 67.6 loads, so 240 loads need 3.55 vehicles: 4, the AGV Fleet Size calculator's own example. For several routes the workbook adds every route's vehicle minutes first.
What cycle time should I use for a route?: One complete trip: pick-up, loaded travel, drop-off, any waiting at the stations and the empty return or reposition before the next mission. Time real trips or take them from the supplier's route study. Leave charging out of the cycle time if it is already in the availability figure, so it is not counted twice.
Why plan the fleet below 100% utilisation?: At 100% every vehicle is busy all the time it is available, so any traffic, queue at a station or burst of demand makes loads late. The planning limit on Setup is your choice; at 100% the workbook matches the calculator's sizing. In the example the routes need 8 vehicles at 100% and 9 at an 85% limit.
Shared fleet or dedicated vehicles per route?: A shared fleet pools the fractions: a route that needs 1.4 vehicles and one that needs 0.6 share two vehicles, while dedicated vehicles would need three. In the example the shared plan needs 9 vehicles against 11 if every route had its own. Dedicated vehicles still make sense where routes need different vehicle types or a fixed delivery rhythm.
Does the template size chargers or check traffic?: No. Charging time belongs in the availability figure, and chargers are sized with the Charging Station Count calculator. Congestion, shared lifts and doors, and dispatch rules can need more vehicles than the averages show, so confirm the fleet with the supplier's simulation.
Does the workbook use macros?: No. It is a plain .xlsx with ordinary formulas, tables and native charts, so it opens without enabling macros. The Verify sheet re-checks the formulas against fixed test cases and shows Self-check: PASS.