Heavy Payload AMRs vs. Forklifts: When to Switch (and When Not To)

Finding the right way to use AMRs and Forklifts is key to updating your warehouse

Forklifts are great at flexible moves and surge scenarios. Heavy-payload AMRs shine where routes repeat, safety risk is high, or labor is tight. The trick is knowing where each wins—and by how much.

The decision drivers

• Throughput & repeatability: If >60% of pallet moves follow repeatable lanes (dock → buffer → line feed), AMRs can cut travel waste and idle time.

• Safety & exposure: AMRs reduce human-in-vehicle incidents and near-misses, especially in mixed-traffic aisles and blind corners.

• Aisle width & flow: AMRs can work in narrower aisles with defined traffic rules; forklifts excel in tight, ad-hoc maneuvering (staging, high-bay put-away).

• Utilization & shift coverage: AMRs run predictable shifts with scheduled charging; forklifts win when demand is spiky and ad-hoc.

• Changeover agility: Route updates are software changes for AMRs; forklifts pivot instantly but rely on driver availability and training.

A quick ROI sketch (use your numbers)

1. Baseline: trips/day × meters/trip × labor minutes/trip × labor cost/min.

2. Forklift OpEx: labor + maintenance + fuel/electricity + incidents/downtime.

3. AMR TCO: lease/purchase + maintenance + power + fleet software + commissioning.

4. Compare: Include safety costs (near-misses, minor incidents) and quality impacts (line starvation, misroutes).

Rule of thumb: If each lane moves ≥120 pallets/shift over ≥250 m with steady utilization, AMRs often beat forklifts on cost per move and incident exposure.

Where AMRs win

• Fixed lanes (dock↔buffer, buffer↔line feed)

• 2–3 shift operations with predictable volume

• Sites prioritizing safety and standardized flow

Where forklifts still rule

• Heavily variable, ad-hoc tasks (odd-size loads, rework, rapid re-slotting)

• Long outdoor runs, ramps, or rough floors

• Extreme surge periods without spare AMR capacity

Implementation pitfalls (and fixes)

• Underpowered traffic rules: Define yields, crossings, and speed zones day one.

• Charging blind spots: Place bays near idle areas and schedule top-up charging.

• IT surprises: Confirm WMS/WES integration and device certificates early.

5-minute checklist

• ≥60% of moves are repeatable lanes

• Aisles marked; crossings can be gated/signed

• WMS/WES endpoints ready; Wi-Fi/5G coverage mapped

• Floor flatness & payload specs confirmed

• Safety case drafted (zones, signage, e-stops, SOPs)

Want a lane-by-lane ROI? We’ll simulate your flows and return a 1-page decision with cost, safety, and throughput impacts.