Determination of optimal Automated Guided Vehicle fleet size for a flexible manufactured system

The required number of AGVs necessary to perform a given level of material handling task in an FMS environment is determined using analytical and simulation modelling. The analytical method involves consideration of load handling time, empty travel time, and waiting and blocking time. Load handling time is computed from given system parameters. Determination of empty vehicle travel is difficult due to the inherent randomness of an FMS. Several research studies for this purpose are discussed and a new model is proposed. It entails formulation of a mixed integer programme with an objective of minimizing empty trips. The constraints are in the form of upper and lower bounds placed on the total number of empty trips starting from or ending at a load transfer station. The phenomena of vehicle waiting and blocking are also discussed. The cumulative impact of these three time estimates are then translated into an initial estimate of AGV fleet size as predicted by individual models. The method is applied to an illustrative example. Finally, simulation methodology is used to validate the initial estimates of fleet size. The results indicate that the different models either under-estimate or over-estimate the actual number of vehicles required in the system. The proposed model, though it under-estimates the minimum AGV requirement, yet provides results which are close to the simulation results. Hence, it can be used as an analytical tool prior to the simulation phase of AGV design.