At some stage, most materials handling operations find themselves running mixed fleets of equipment
In materials handling environments, it is virtually unknown for automation to be introduced overnight, in one complete transformation. For most businesses, the process is gradual.
According to Wang Zhenyu, overseas sales leader at Hangcha Intelligence, there are several reasons for this. The first relates to capital expenditure and return on investment.
“A full-scale, overnight automation project requires massive upfront investment,” says Zhenyu. “In contrast, a phased approach allows companies to justify the investment step-by-step, with each phase funding the next through demonstrated returns like labour savings and productivity gains.”
Another reason is the operational disruption that wholesale transformation would cause.
“Shutting down a warehouse or production line for a complete retrofit is not feasible for most businesses,” says Zhenyu. “Gradual integration allows for deployment without interrupting ongoing operations, minimising risk and ensuring business continuity.”
And the third reason falls under the category of “organisational readiness”.
Beyond products like this mini reach AGV, Hangcha is able to help its clients meet the challenges of managing mixed fleets
“Staff need training to work alongside and manage new technology,” adds Zhenyu. “Processes need to be adapted. A gradual journey allows the organisation to learn, adapt, and build internal expertise at a manageable pace, ensuring long-term success.”
Starting points for automation
Matilda Suonpää, product manager, warehouse logistics solutions management at Rocla AGV Solutions, agrees and says taking a step-by-step approach also addresses the trepidation around new technologies.
“The new system can be integrated without upheaval, as teams can adapt and learn as they go,” says Suonpää.
“Because these solutions are highly scalable, businesses can start with a single process and expand as their needs evolve. It’s not a daunting task. It’s simply adjusting to a new way of working.”
Taking this approach, automation tends to start with the most repetitive and predictable tasks, such as transporting goods from one location to another, picking up or dropping off at conveyors, or handling high-lift racking.
“These are ideal starting points because they follow consistent patterns and can be easily optimised,” says Suonpää.
From there, businesses are in a position to analyse the rest of their operations and identify further opportunities for improvement.
"Managing a mixed fleet of automated equipment presents significant challenges that can hinder operational efficiency and scalability."
The mixed fleet phenomenon
One unintended consequence of this gradual approach is that those who follow it are generally left with mixed fleets of equipment. They find themselves either running automated equipment alongside traditional equipment or running multiple brands of automated equipment alongside each other.
Wellwit recommends the use of agnostic Fleet Management Software alongside mixed fleets of equipment
“Managing a mixed fleet of automated equipment presents significant challenges that can hinder operational efficiency and scalability,” says Henry Peng, CEO of Wellwit Robotics.
The first relates to integration and inherent communication barriers.
“Different brands often operate on proprietary communication protocols and data interfaces,” says Peng.
“This creates ‘islands of automation’, in which equipment cannot effectively ‘talk’ to each other or to the central Warehouse Management System (WMS), leading to coordination failures and data silos.”
Then there is the issue of fragmented control systems. Without a unified platform, operators may need to juggle multiple software systems to control different brands of robots.
“This makes it incredibly difficult to optimise task prioritisation, path planning, and traffic flow, increasing the risk of congestion and collisions,” says Peng.
And finally, running mixed fleets complicates the task of maintenance which, in turn, drives up training costs, lengthens repair times, and increases overall operational risk.
According to Peng, overcoming these challenges requires a strategic focus on openness, standardisation, and partnership.
“Selecting equipment that supports industry-standard communication protocols (such as VDA5050) is a critical first step. This creates a common language, forming the foundation for seamless integration,” he says.
The next step involves investing in a robust, agnostic Fleet Management Software system.
“These system act as a ‘central orchestrator’, capable of receiving tasks and intelligently dispatching all compatible robots – regardless of brand – to optimise overall workflow and efficiency,” says Peng.
In terms of vendors, businesses should seek those who see themselves as not just hardware suppliers but collaborative ecosystem players.
“Look for partners who offer open Application Programming Interfaces (APIs) and provide dedicated technical support to facilitate integration into your chosen management system,” says Peng.
Meeting the challenges
Importantly, each of the suppliers mentioned has the expertise to help its clients meet the challenges of managing mixed fleets.
For example, Hangcha’s key point of difference is its software platform, the Xpress Fleet Management System, which Zhenyu describes as its “command centre”.
Designed for interoperability, the system has the capacity to manage Hangcha’s own vehicles and also, thanks to its open interfaces, to integrate with other brands of equipment and higher-level warehouse systems.
In addition, the company offers the Grace Robot Control System (RCS), a robust middleware system that provides low-level control and optimisation for its own fleet of robots.
“We don't just sell robots,” says Zhenyu. “We provide full-cycle support from consultation and system design to implementation, integration, training, and lifelong maintenance, ensuring a seamless fit into your operations."
Rocla's FleetController is an intelligent software system that extends automation benefits to manual operations
Meanwhile, Rocla AGV Solutions offers a comprehensive range of solutions designed to support efficient and safe materials handling in mixed environments.
“Our automated guided vehicles (AGVs) are equipped with a user-friendly interface and advanced navigation capabilities, making them easy to integrate and operate within existing workflows,” says Suonpää.
In addition, Rocla AGV Solutions offers FleetController, an intelligent software system that extends automation benefits to manual operations.
Enabling centralised task allocation and coordination across entire fleets (of automated and manual equipment), it helps improve material flow and overall efficiency.
Safety concerns
Aaron Zhu, US general manager at Multiway Robotics stresses the importance of safety in the context of mixed fleets and says operators are right to be wary of potential hazards, such as collision risks or system malfunctions.
Multiway Robotics stresses the importance of safety in the context of mixed fleets
“To mitigate these, companies typically begin with high-frequency, repetitive, or high-risk workflows where the benefits of automation are clear and immediate,” says Zhu.
“By taking a phased approach, businesses can reduce labour strain, improve accuracy, enhance safety, and build confidence in automation – leading to broader adoption as the technology proves itself.”
Multiway Robotics offers a full portfolio of CE-certified AGV forklifts – including counterbalanced, sideloader, stacker, VNA (Very Narrow Aisle), and cold chain AGVs – as well as intelligent four-way shuttles.
According to Zhu, these products enable automated transport and storage across diverse environments, reducing labour dependence, increasing throughput, and minimising cargo loss.
“Beyond equipment, we integrate WMS, Warehouse Control Systems (WCS), and RCS for unified scheduling, data-driven warehouse management, and seamless cross-system connectivity,” says Zhu.
Coupled with its ‘Vision System’ monitoring platform, which ensures full-site visibility of people, vehicles, and goods, the company delivers a safe, efficient, and intelligent logistics ecosystem tailored to dynamic production needs.
“Our intelligent logistics solutions have reached more than countries and regions, and are empowering 20-plus industries worldwide,” says Zhu.
“With 450-plus patents and software copyrights and over 1,000 successful projects, we deliver proven innovation on a global scale.”
"No single provider can offer everything, and no plant uses just one robot."
Catering for diverse environments
Miya Gong, head of marketing at SEER Robotics, says the fact that industrial environments vary so widely, is another reason so many find themselves with mixed fleets.
SEER Robotics' all-in-one logistics management system connects equipment, such as this AGV, with business systems
“No single provider can offer everything, and no plant uses just one robot. That’s why we offer a complete solution covering development, deployment, and management,” she says.
Given that SEER Robotics offers a leading robot control system and has partnered to develop over 1,000 robot types, Gong is well-placed to make this point.
“These ready-to-use robots can be accessed directly through our Nebula system. For custom development, we also offer over 300 plug-and-play robot accessories, plus developer training and full support,” she says.
To eliminate information silos, the company’s all-in-one logistics management system connects robot platforms with business systems. On top of this, it includes low-code development tools to simplify custom integration and make systems more flexible and scalable.
Asked for an example of her organisation’s work, Gong nominates a Philips warehouse in the Netherlands, at which SEER Robotics deployed a flexible and efficient robot solution.
Considering the context, which involved human-robot collaboration, SEER selected the SFL-CDD14-CE stacker robot (which features a 3D camera, distance sensors, and 360° active protection), powered by its safety-rated SRC-3000FS controller and certified with CE and UL.
“We redesigned the workflow, optimised the robot’s routes and pallet positions, and fine-tuned its safety settings. Specific safety zones were set up, and emergency actions could be triggered with a single click – ensuring both safety and efficiency in a complex environment,” says Gong.
As a result of the deployment, transfer speed improved, the need for manual labour reduced, and site safety was enhanced.
Real-time location systems
The final word on managing mixed fleets of materials handling equipment goes to Yael Fainaro, president and chief business officer at RGo Robotics.
RGo Robotics' technology turns any moving machines into a smart, trackable asset
“Buying from multiple suppliers makes business sense – you get the best equipment for each specific task,” she says. “However, different machines have different spatial awareness capabilities, making coordination challenging for optimised, safe flow.”
According to Fainaro, equipment manufacturers sometimes offer add-ons or built-in spatial awareness capabilities, but these often work only with their own equipment and specific models.
“For effective coordination, all machines need similar basic capabilities aligned to a common, shared view,” she says.
“This is why operators are installing real-time location systems (RTLS) that provide visibility across their entire fleet and a site-wide view.”
Asked for an example, Fainaro points to RGo’s visual RTLS solution, a machine-level localisation system that makes RTLS implementation feasible for any warehouse, even those with small fleets.
RGo's localisation box retrofits to any moving machine, regardless of make, size, or operation mode (robotic, manual, or hybrid) and requires no significant infrastructure modifications.
Mapping occurs automatically, during normal operations and without disruption, and the solution integrates seamlessly across various environments.
In addition, according to Fainaro, the solution is versatile.
“Through simple API integration, RGo's information can track goods carried by machines, set up and enforce safety zones, generate automatic operational insights, and much more,” she says.
In this way, like the various other solutions mentioned above, it helps address the challenges associated with managing mixed fleets of materials handling equipment and ensures those who implement it are well-placed to reap the benefits of automation.
Discover more about the advancements in mixed fleet operations from our contributors by visiting our Virtual Expo.
For this report we interviewed the following industry specialists:
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