Getting Traction with Mobile Robots

Before a vehicle is ever built, engineers are digging into the details: load requirements, clearances, floor conditions, environmental factors, maintenance access, safety considerations, and even how the system may need to adapt years down the road.

In this episode of Getting Traction with Mobile Robots, Emily sits down with David Moses, Engineering Manager, to pull back the curtain on the engineering process behind an AGV system and explore the decisions that can affect its performance, serviceability, longevity, and overall value.

In this episode, we'll cover:

• What happens when an AGV project moves from sales to engineering
• Why load weight is only part of the equation when designing a vehicle
• How floor conditions, clearances, temperature, humidity, and other environmental factors influence AGV design
• Why serviceability and maintenance access need to be considered before the vehicle is built
• How engineering, production, fabrication, maintenance teams, and customers contribute to the design process
• When a standard AGV approach works and when customization becomes necessary
• Real-world examples of unexpected customer requirements that changed the engineering solution
• How designing for future changes and retrofits can help customers get more long-term value from their systems

One of the biggest takeaways from the conversation? Good AGV engineering isn’t just about making a vehicle work today. It’s about thinking through the details now that could become problems, or opportunities, years down the road.

Timestamps:

00:00 – Introduction

02:16 – What happens after a customer says yes to an AGV project?

05:35 – What customer assumptions does engineering need to verify?

07:00 – Designing for maintenance and serviceability

08:11 – Why AGV engineering is a team effort

10:10 – Solving problems before they happen

12:30 – Planning for future changes and expansion

13:05 – When a custom solution becomes necessary

14:55 – How design reviews help uncover overlooked requirements

16:10 – How floor conditions can affect AGV performance

17:30 – Environmental factors: temperature, humidity, dust, and debris

20:30 – Standard vs. custom: how engineers decide

22:10 – What matters most years after an AGV project is installed

🎧 Watch/listen to the full conversation to hear how the engineering decisions customers rarely see can shape how an AGV performs on the plant floor for years to come.

Interested in AGVs for your operation?

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

Follow America In Motion

LinkedIn: https://www.linkedin.com/company/america-in-motion/

Facebook: https://www.facebook.com/AIMAGVs/

YouTube: https://www.youtube.com/channel/UCwtZWaJOw-9YWzkuC0T048w

How long should an AGV system actually last?

The answer isn’t simply a number. How often the vehicle runs, how it was designed, battery selection, preventive maintenance, documentation, and even whether the right spare parts are sitting on the shelf can all play a role.

In this episode of Getting Traction with Mobile Robots, David Moses, Engineering Manager at America in Motion, breaks down the practical decisions that can help manufacturers get more life and value out of their AGV systems.

• Why preventive maintenance beats reactive maintenance
• How operating hours affect maintenance schedules and expected life
• What wheels, bearings, gearboxes, ball screws, and other components can tell you before a failure
• The tradeoffs between lead-acid and lithium batteries
• Why maintenance documentation matters across shifts
• How spare-parts planning can reduce downtime
• How design decisions made before an AGV hits the plant floor can influence its longevity

One of the simplest takeaways from the conversation? Treat an AGV a lot like your car: take care of what you already have instead of waiting for something to break.

00:00 – Introduction

01:29 – How long should an AGV system last?

03:26 – What helps an AGV reach a 15–20 year service life?

04:39 – Maintenance practices that influence longevity

05:37 – How do you know when maintenance is due?

06:37 – Who should be responsible for AGV maintenance?

09:22 – Battery management and system health

10:44 – Lead-acid vs. lithium batteries

12:21 – How small maintenance issues become expensive problems

14:44 – How AGV design decisions affect longevity

16:52 – Why maintenance documentation matters

18:31 – The big takeaway: plan ahead and keep critical parts on hand

🎧 Listen to the full conversation to hear David Moses explain how manufacturers can think beyond installation and plan for the AGV’s entire working life.

Interested in AGVs for your operation?

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

Follow America In Motion

LinkedIn: https://www.linkedin.com/company/america-in-motion/

Facebook: https://www.facebook.com/AIMAGVs/

YouTube: https://www.youtube.com/channel/UCwtZWaJOw-9YWzkuC0T048w

Implementing AGVs and mobile robots doesn't have to mean production chaos.

In Episode 6 of Getting Traction with Mobile Robots, host Emily Pallikan sits down with Chase Eklund, Product Development Manager at America in Motion, to discuss one of the biggest concerns manufacturers have when considering automation:

How do you implement AGVs without disrupting production?

Chase shares a behind-the-scenes look at what a successful AGV rollout actually involves, from facility surveys and virtual testing to phased implementation strategies and customer collaboration. He explains how modern automation projects minimize downtime through simulation, validation, and careful planning before a single vehicle arrives on-site.

Whether you're exploring automation for the first time or looking to expand an existing system, this episode provides a practical look at how AGV implementations are designed to protect production schedules while delivering long-term operational gains.

✅ Common misconceptions about AGV implementation

✅ How phased rollouts reduce production risk

✅ The role scheduling plays in successful automation projects

✅ How AGVs integrate with existing automation systems

✅ Why short-term downtime often leads to long-term gains

✅ Real examples of AGV systems still running after 15+ years

01:41 Episode overview: implementing AGVs without disrupting production

03:07 The biggest production schedule concerns manufacturers have

04:04 The AGV implementation process explained

05:30 Minimizing downtime through planning and scheduling

07:22 Working through bugs before deployment

10:09 Does every AGV implementation require a shutdown?

11:03 Why AGV ROI often outweighs short-term disruption

11:42 What a phased rollout looks like in a real facility

13:57 The hidden complexity behind AGV systems

14:57 The orchestra analogy: automation working together

15:21 Common mistakes companies make during AGV rollouts

16:27 Why scheduling is critical to implementation success

17:43 Real-world example of a tightly planned installation window

19:55 The backstage work required before automation goes live

21:14 Planning for unforeseen delays and contingencies

22:44 Advice for manufacturers worried about production disruption

23:33 Why invest in AGVs in the first place?

24:15 Customer success story: AGV system operating for 18 years

26:47 Final advice for companies considering automation

27:30 Closing thoughts and additional resources

Interested in AGVs for your operation?

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

Implementing Automated Guided Vehicles (AGVs) is about more than technology. Even the most advanced system can struggle if the workforce isn't prepared for the change.

In this episode of Getting Traction with Mobile Robots, Emily sits down with Chase Eklund, Product Development Manager at America in Motion, to discuss what happens when AGVs arrive on the plant floor, how employees typically react, and what companies can do to create a smooth transition. From addressing safety concerns to effective training strategies, they share practical insights for leaders preparing their teams for automation.

• Why AGVs often create a "shell shock" reaction when first introduced
• Common employee concerns about safety and autonomous equipment
• How AGV safety systems work in shared environments
• Best practices for workforce training and education
• The importance of hands-on demonstrations and real-world examples
• How facility operations may need to adapt for AGV success
• The role of an internal "AGV Champion"
• Tips for preparing employees before implementation begins
• Why awareness and communication are critical to long-term adoption

00:00 Introduction: Why workforce preparation matters

02:35 First reactions employees have when AGVs arrive

03:41 Understanding common safety concerns

06:04 Building trust through demonstrations and hands-on interaction

07:30 The mindset shift required for successful AGV adoption

08:40 AGV training vs. forklift training

10:20 Who should be trained on an AGV system?

11:50 The importance of an AGV Champion

14:45 Preparing your workforce before AGVs arrive

15:42 Creating an open learning environment around automation

16:37 Key takeaways: safety, awareness, and building confidence

18:03 Comparing AGVs to other technology advancements

19:12 Closing thoughts

Interested in AGVs for your operation?

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

How do AGVs fit into a larger automation system, and who should be responsible for making everything work together? In this episode of Getting Traction with Mobile Robots, Emily Pallikan sits down with Terri Blasius, Vice President and Co-founder of America In Motion, to explore the role AGVs play in connecting conveyors, robot cells, warehouse software, doors, and other automation technologies. They discuss the different levels of integration, when an AGV provider should act as the integrator, and why understanding integration ownership early can prevent costly project delays.

The conversation also highlights one of the biggest obstacles in automation projects: IT. From networking and security requirements to remote access and system communications, Terri shares practical lessons from real-world deployments and explains why involving IT from the beginning is critical to a successful implementation.

If you're evaluating or planning an automation project, this conversation will help you understand integration ownership, avoid common pitfalls, and bring the right stakeholders into the process from day one.

• Why networking and communication are usually the hardest part of integration
• OPC tags and an OPC server as the central translation layer for most automation systems
• How a central OPC hub can read signals like package presence and share them across devices
• Why AGV projects often need a mix of OPC, database connections, APIs, web services, and sometimes legacy flat files
• The three integration levels
• How contract ownership affects who can actually direct robot, conveyor, or cell vendors
• Why AGVs are often seen as the natural integrator because they move between all the other systems
• The importance of early customer education about who should own integration
• Remote access as a practical support solution
• The value of retraining and documentation when customer turnover happens after installation

00:00 Introduction

02:10 Role AGVs play in integration

02:45 OPC tags and the central communication hub

04:53 Choosing the right integration method

06:05 Why AGVs companies are often a natural integrator

07:12 Explaining integration roles to customers

09:26 Three levels of integration projects

11:47 Integrating for future and beyond

13:00 How being integrator can give you greater control

14:13 Why networking and IT are the real hurdle

15:14 Get IT involved early or pay for it later

16:40 Retraining after turnover and keeping documentation ready

17:13 Remote access can make or break support

18:06 Troubleshooting bad tags, blocked ports, and tuning

19:18 How data moves from warehouse systems to AGVs

21:25 Reusing tools across different integration setups

22:08 The biggest takeaway: IT first, then integration

23:19 Knowing your integration level helps you choose partners

Interested in AGVs for your operation?

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

The vehicles move material, but software is what connects people, processes, and automation across your operation.

In Episode 3 of Getting Traction with Mobile Robots, host Emily Pallikan sits down with Terri Blasius, Co-Owner and Executive Vice President of America In Motion, to discuss one of the most overlooked aspects of AGV deployments: software integration.

From simple call-button applications to complex ERP and WMS integrations, Terri explains how software serves as the coordination layer that helps conveyors, robot cells, warehouse systems, and mobile robots work together. The discussion also covers open versus closed software, the risks of vendor lock-in, and why involving IT early can help set automation projects up for long-term success.

Whether you're evaluating your first AGV system or planning for future growth, this episode will help you better understand the software decisions that can impact flexibility, scalability, and ownership for years to come.

✅ AGV software acts as the coordination layer between equipment, systems, and workflows.

✅ Understanding the difference between open software, closed software, and open-source software is critical when evaluating automation providers.

✅ Vendor lock-in can limit flexibility and create challenges as operations evolve.

✅ Integration requirements can range from simple vehicle controls to complex ERP and WMS communication.

✅ More manufacturers are building internal automation expertise and taking greater ownership of their systems.

✅ Involving IT early helps avoid integration headaches later in the project.

✅ Data visibility, dashboards, and system insights are becoming increasingly valuable for operations teams.

✅ Scalable software creates a foundation that can support future growth and changing business needs.

Timestamps:

02:03 —The role software plays in AGV integration

03:01 — What is “open” software and the benefits

03:56 — Limitations of closed software

05:06 — Why most AGV users don't need source code

06:20 — Three levels of integration ownership

07:01 — Creating automation teams for AGV success 

08:31 — Examples of integration roles

10:59 — Having control over your AGV system

11:54 — IT and software support 

14:24 — Scalability of software for future growth

18:25 — Picking a vendor for best AGV software

13:42 — Bring IT in early

15:00 — Supporting AGV systems over time

17:30 — A full workflow example from order to execution

20:42 — What teams often overlook

20:28 — Final insights: AGV software should adapt to you and your operations 

Interested in AGVs for your operation?

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

When companies evaluate automation, labor savings usually get all the attention. But some of the most significant costs in an operation come from somewhere else entirely: damages.

In this episode of Getting Traction with Mobile Robots, host Emily Pallikan sits down with Tommy Hessler, CEO and cofounder of America In Motion, to discuss the hidden costs associated with manual material handling and why many manufacturers underestimate their impact.

From damaged products and pallets to facility repairs, rework, safety incidents, and operational disruptions, damage often becomes accepted as "the cost of doing business." Tommy explains how AGVs change that mindset by bringing consistency, predictability, and greater visibility to material handling operations.

If you're evaluating automation solely through the lens of labor reduction, you may be missing a major part of the ROI equation.

Key Topics Covered

• The often-overlooked costs associated with damages in manual versus automated material handling
• How damages accumulate over time and impact overall ROI
• The role of automation in reducing damage variability and improving safety
• The importance of comprehensive cost analysis beyond labor savings
• Practical methods for quantifying damages through throughput analysis and presumptive calculations
• Industry-specific examples, including textiles and packaging, illustrating damage mitigation
• The future of AGVs in enhancing environmental and safety standards
• Tips for engaging financial decision-makers with damage-related data

Timestamps:

00:00 - Introduction to damages in AGV systems and why it matters

01:36 - Set the stage: Costs of damages in manual vs. automated handling

05:04 - The significant value of transported loads and damage impact

06:17 - The difficulty of measuring damages in practice

04:52 - Visualizing total cost breakdown and payback periods

07:14 - Lessons from textile industry leak detection and measurement

08:28 - The role of automation in handling damages more consistently

09:29 - Damage variability caused by human drivers and how automation reduces it

10:56 - Environmental benefits: Noise reduction and pollution considerations

12:19 - Enhancing safety with programmed speed controls and pedestrian gates

13:00 - The misconception that AGVs will replace human jobs; instead, they free workers for smarter tasks

13:34 - Complete control over AGV behavior and operational safety protocols

13:54 - Innovative approaches: Flexible plant layouts with non-linear AGV operations

14:41 - Industry pioneers: Volvo’s early autonomous vehicle experiments

16:10 - Practical advice for quantifying damages and assessing ROI

17:07 - Simple calculations to estimate damage costs over time

18:01 - Risks of ignoring damages: Misjudged payback and missed improvement opportunities

18:51 - Final insights: Talking to financial decision-makers and making data-driven choices

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

The price of an AGV is only part of the story. In this first episode of Getting Traction with Mobile Robots, host Emily Gregory sits down with Tommy Hessler, CEO and co-founder of America In Motion, to break down the real costs behind a successful AGV deployment.

Learn the difference between vehicle cost and system cost, the major cost categories buyers should expect, why quotes can vary dramatically from one supplier to another, and how to evaluate long-term value beyond the initial purchase price.

Whether you're exploring automation for the first time or planning your next project, this episode will help you make more informed AGV investment decisions.

• The difference between AGVs and AGV systems, including infrastructure needs
• The major cost drivers: hardware, intelligence, safety, and safety systems
• The importance of scalability and flexibility for future growth
• Cost implications of choosing Chinese-made vs. American-made AGVs
• Total cost of ownership including maintenance, support, and battery systems
• Critical role of planning, flow analysis, and simulation to avoid overinvesting
• The value of an AGV champion in your organization to ensure successful adoption
• Long-term benefits: efficiency gains, damage reduction, and safety improvements

00:00 - Introduction

01:20 - Welcome Tommy Hessler

02:00 - Why understanding AGV costs is crucial for automation success

02:55 - Differentiating between AGVs and AGV systems 

05:53 - Various infrastructure components of AGV system (fleet manager, tracking, etc.)

07:31 - Cost ranges for simple vs. complex, highly integrated AGV systems

09:34 - Battery types, management, and their effect on ownership costs

12:15 - Considering Chinese-made vs. U.S.-made AGVs in your purchasing decision

13:55 - The importance of support, software, and system flexibility

14:40 - Planning for growth, retrofit potential, and long-term adaptability

18:47 - The differences in buying an AGV system versus a car and the buying experience

19:26 - The importance of virtual planning and simulation before implementation

22:04 - Total cost of ownership, including maintenance and IT support

24:32 - What companies should be thinking about financially when investing in AGVs

27:42 - Differences between AGVs and forklifts, why simulation matters and proper training

30:07 - Key questions for financial planning and ROI estimation

30:54 - Final remarks

Interested in AGVs for your operation?

🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction

📊 Start Planning Your AGV System

Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system

🤝 Talk to an AGV Expert

Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation

Getting Traction with Mobile Robots is the podcast for manufacturers, warehouse operators, and automation leaders exploring the world of AGVs, AMRs, and industrial automation.

Hosted by America In Motion, each episode features conversations with industry experts, engineers, software specialists, and automation leaders who answer the questions manufacturers are already asking—from calculating ROI and selecting the right software to managing implementation risks, overcoming integration challenges, and ensuring long-term system success.

Whether you're just beginning your automation journey or looking to optimize an existing system, Getting Traction with Mobile Robots delivers practical insights to help you make informed decisions and move your operation forward with confidence.

🎙️ New episodes every other Tuesday.

Subscribe now and start getting traction with mobile robots.