EVALUATION OF LAYOUT DESIGN,

OPERATION, & MAINTENANCE OF

MULTI SYSTEM AUTOMATED
GUIDED VEHICLES

Suparjon Automated Guided Vehicle (AGV) is a type of vehicle that is driverless

Mahasiswa S2
Program Megister, Jurusan
Teknik Mesin Fakultas Teknik
Universitas Brawijaya Malang
suparjon@student.ub.ac.id
Muhammad Ilham
Mahasiswa S2
Program Megister, Jurusan
Teknik Mesin Fakultas Teknik
Universitas Brawijaya Malang
mohilham083@student.ub.ac.id
Yudistira
Mahasiswa S2
Program Megister, Jurusan
Teknik Mesin Fakultas Teknik
Universitas Brawijaya Malang
Yudistira@gmail.com
and is programmed to run on a predetermined route to transfer loads.
The objective of this study was to develop an approach to design an
optimal flow path for AGVS. Hence the aim of the work presented in
this paper is to demonstrate the advantages of applying this evaluation
of layout design, operation, and maintenance of multi system
automated guided vehicles (AGV). The results obtain from this study
can help the management in making strategic and tactical decisions
relating to process layout, operations, and maintenance improvement
for improving the efficiency and performance of a manufacturing
system . The results can be verified by simulating the entire problem.
Simulation would take in account the travel of unloaded vehicles,
buffering, congestion and other control aspects, it would give a more
complete picture of the system. Formulating the programs takes less
time than building a simulation model and could be solved in less time.
So, using the mathematical programming a layout may be generated
and then tested using the simulation. The environments in which the
approach is best suited are flexible ones, i.e., more specifically where,
optimal flow path may change as the material flow intensity in from-to
chart changes. Assuming that the departmental layout design,
operation and maintenance other assumptions do will increase,
constraints of the problem remain the same. All that will change is the
coefficients of the objective function.

Keywords: Automated; Guided; Operation; maintenance; system

1. INTRODUCTION
Global competition and changing customers demands, has made the manufacturing companies to look for new
manufacturing systems which can fulfil their requirements for global competition [1]. The survival and growth
of manufacturers depend on their ability to offer a great variety of high-quality products at an acceptable price
using minimum lead time [2]. Globalisation has given thrust on the engineers and managers of manufacturing
organisations to manufacture their products, with high quality at a lower cost [3]. The development in the
technology now a day’s confront manufacturing systems to a variety of alternatives for in-plant transportation.
The material handling system (MHS) proven to be the backbone of a flexible manufacturing system (FMS). The
performance of the whole facility is directly affected by the performance of the MHS. With the current pressures
on manufacturing companies to cut the costs, AGVS have proven themselves as an effective means by reduction
in the cost of labour. In modem manufacturing systems, AGVS is the most widely used MHS in FMS which
enhances the flexibility in material transfer between the workstations. Automated guided vehicles (AGVs) are
fully automated, battery-powered vehicles that are able to transport goods in a logistic or production
environment [4].
Automated Guided Vehicles (AGVs), a type of vehicles that are driverless and programmed to travel on
predefined routes to transfer loads, are being widely used in modern material handling systems due to their
ability to improve the efficiency and productivity of the systems and decrease human labour. Accordingly, the
design, operation and maintenance of the AGV systems have attracted interest from both academic and
industrial communities in recent years. In particular work on improving the efficiency, and lowering the
operation cost, of AGV systems has been performed [5][6].
Automation in manufacturing is demanded continuously since it saves labors and materials to improve
quality, accuracy, precision and efficient [7]. Take a smart factory for example, some cutting-edge technologies
such as cyber-physical systems (CPS) is employed to monitor physical processes through creating a virtual
world so that manufacturing automation could be achieved by modularized and structured units [8].
Manufacturing systems using CPS technology play an important role in a smart factory. Within such systems,
information from all related production activities will be closely synchronized and monitored between physical
factory floor and cyber computational space [9]. One of the key features of the Smart Factory is the logistics
automation that allows the delivery of various components in the plant efficiently as a workshop.
The logistics automation could be realized by automated guided vehicles (AGVs) which are able to move
different materials like raw-materials, work-in-progress items, and finished products in a flexible manner
without human interventions [10]. The high synchronization of manufacturing activities and logistics behaviors
must be ensured so that the production could go smoothly. There- fore, positioning system for AGVs is crucial
since determination of the location of an AGV will largely influence the entire manufacturing system. Machines
and workers may spend extra waiting time for the arrival of materials if the AGVs’ positioning system cannot
work properly. Additionally, manufacturing performance heavily relies on the logistics efficiency and
effectiveness within a smart factory where highly automated machines will be equipped. That brings great
challenges for the positioning system in an AGV because its system layout and performance will greatly be
affected by manufacturing facilities and situations such as dynamic changes or emergency production orders
[11]. Currently, fixed guide paths with magnetic bands are widely used for positioning system due to its low
cost [12]. However, this approach cannot fit the manufacturing flexibility since the facilities within a smart
factory will be recon- figured and redesigned given different mass customize products. For example, the
manufacturing machines may follow production line mode in peak-season and then follow another mode by
group in these machines with similar functionalities in off-season. Fixed guide paths thus should be revised with
more efforts in terms of labor and time cost.
As the development of Auto-ID technologies like radio frequency identification (RFID), the positioning
systems for AGVs for smart factories could be improved. Some primary studies show the feasibility and
practicality of using RFID for AGV’s positioning in typical manufacturing factories. For example, RFID was
used for positioning by placing readers and tags upon manufacturing environment so as to facilitate the
automatic logistics through a cloud or remote controller [13]. Passive RFID is used in an indoor position tracking
system based on a precise tracking algorithm [14]. Automated Guided Vehicle (AGV), a type of vehicle that is
driverless and programmed to perform running on a predetermined route to transfer load. While it is widely
used in modern material handling systems because it is for their ability to improve the efficiency and
productivity of the system and reduce human work. The functions of the AGV are aimed to drastically reduce
the time, cost and personnel involved in the industry [15].
With the continual scaling up and modernization of AGV systems in recent years, they are now designed
to deliver more complex tasks. Accordingly, more and more uncertainty issues are observed in the systems. For
this reason, the failure management and maintenance strategies of AGVs are identified as new challenging
issues that need to be addressed. As the rate of application of AGVs continues to increase the need to resolve
such issues has become a pressing task. Some studies have been undertaken in the literature to achieve this. For
example, the safety requirements and safety functions for a decentralized controlled AGV system were in
discussed [16]. More recently, the reliability of AGVs was modelled as a cost function to optimize the time and
cost of the operation of AGV.
Automated guided vehicles (AGVs) with autonomous behavior are suitable for use in logistics [17]. To
facilitate natural communication, decentralized human–machine interaction (HMI) may involve both speech
and gesture control. Speech commands are more efficient for issuing orders (e.g., ‘‘AGV 3, take pallet from
floor’’). By contrast, referencing (deictic) arm gestures are optimal for assigning objects (e.g., palletized goods
in floor storage) to an AGV in its mobile coordinate system. Combined speech and gesture control is the current
state of the art in many applications. Whereas gesture control primarily requires physical effort, speech control
involves predominantly cognitive effort, as previously demonstrated with regard to the speech control of mobile
phones during driving tasks [18]. In 2013, more than ten thousand industrial accidents involving fork lift trucks
were reported in Germany, approximately one-third with fatal con- sequences [19]. Possible causes may lie in
excessive cognitive workloads of the users, for example, in the form of insufficient alertness or an unrelaxed
state of mind.
In general, cognitive decision-making support systems are capable of evaluating various features of
sensor signals [20]. The advantages of cognitive-aware technical systems and adaptive production systems have
been shown in [21] [22], respectively. Hence the aim of the work presented in this paper is to demonstrate the
advantages of applying this evaluation of layout design, operation, and maintenance of multi system automated
guided vehicles (AGV) technique to this area. Also, the technique has been adapted in this work and a novel
approach is adopted using five different types of nets which interact to provide the overall system availability.

2. AVAILABLE TECHNOLOGY
2.1 Automated Guided Vehicle
The types of AGV and its use, such as driverless trains, pallet trucks, and unit load carriers. Figure 2.1. Shows
the difference between driver-less trains, pallet trucks, and unit load carriers.

Figure 1: Type AGV (a) driver-less trains, (b) pallets truck dan (c) unit load carriers [23].

The following is a description of the types of AGV driver-less trains, pallet trucks, and unit load carriers.

1. Driver-Less trains
This AGV will draw one or several trailers which will then form the train. This type of AGV is used
to move heavy loads with considerable distances in a warehouse or factory. In its application, can be
determined the location of the capture and decrease of load along the route passed.
2. Pallet Trucks
The AGV is used to move the load in the form of pallets along a predetermined route. In its
application, the pallet retrieval process and the lifting of the cargo using the forklift will be carried
out by an operator. Then, the operator will drive this AGV heading to the guide path, after which the
operator will program to where the payload will be headed and AGV will run automatically to the
place to do the unloading. The capacity of this type of AGV can reach a few kilograms, even some of
which can transport more than one pallet. In its development, the AGV forklift has made progress by
having a vertical velocity (forks) that can put or take pallets on a shelf.
3. Unit load Carriers.
This type of AGV is often used to move the load unit from one station to another. This AGV can do
the loading and unloading automatically by using rollers, moving belts, mechanized lift platforms or
other tools that can move the pallet up to the AGV. The AGV-transportable payload is usually mild
(250 kg or less). AGV is designed to have a small width shape, so it can be used to move small loads
and can pass through a factory that has a limited width of the path. The usual payload is a sub-assembly
that will later be assembled into a product.
2.2 Advantages and disadvantages of AGV
2.2.1 Advantages
There are a lot of advantages for the creation of AGV such as this new brand of vehicles could be safer than
vehicles driven by humans since they are created with a pre-set program that is capable of reacting better than
a human being “Driverless cars are designed to have almost a superhuman-like ability to recognize the world
around them. This is because they use loads of sensors to gather tons of data about their environment so that
they can seamlessly operate in a constantly changing environment.” (Thompson). Nevertheless, these
improvements do not resolve the main problems related to traffic since, another important factor to keep in
mind is that as not every vehicle that travel on the road is an AGV it makes harder for autonomous vehicles to
predict what current vehicles’ –non-autonomous vehicles- behavior will be. Other devices such as traffic lights
are connected to a central network in order to watch over its running. Subsequently, if every vehicle that travels
on the road were AGV, they would be connected to a traffic network in order to avoid collisions, and to make
a decision easily in case of an accident [24].

The advantages of AGV [23], among others.

1. Flexible because it has a guide path, so it can be adjusted to the needs.
2. Improve reliability because AGV drive battery is designed to reach the station to be addressable AGV,
so that the material can be timely.
3. Increase efficiency because AGV does not require operators, so it can reduce the number of workers,
especially in terms of material transfer.
4. AGV can be integrated with other components.
5. AGV is suitable for low production level to medium, distant displacement distance, as well as the
presence of various products and processes.

2.2.2 Weaknesses
One major disadvantage of automated vehicles during crashes is that unlike a human driver who can decide
how to crash in real-time, an automated vehicle's decision of how to crash was defined by a programmer ahead
of time” [25]. Ergo, we can conclude that machines cannot think as a human being would do because their
decision will be based on pre-set information applied to the current situation and if this system fails for
whatever reason, the accident will become inevitable meanwhile a human being will analyses the situation and
then react in just a few seconds.
Besides that, as a brand vehicle is recently is new, is not there a lot of information about the law.
Especially in the US, there is some sort of regulation, but kept continued without answering the questions
important such as: if the case of accidents, who are held responsible? Clearly, the business will be accused
together with Elon Musk, who said that "Tesla simply will take responsibility on the incident when the system
autopilot failed " By because of it, the necessary legislation that covers all cases of accidents, which is provoked
by a car, the driver or system.
Losses Another attend AGV is that the driver will lower the vigilance of them on the street because they
are governed by a system that is capable of driving a vehicle without the need of a rider. As a result, if the
driver relied on the device auto- this and lowered his protector on the road if it happens accidentally, if the
system fails, they are not going to have much time to react because they did not pay attention to the road.
Precisely, 1 st July 2016, the New York Times published a piece of news the following: Joshua Brown died
because of an accident when driving alone was driving a Tesla Model S. [26] Suggests that mobility crashed
into a truck that turned to the left and to the rear that it crashed into a fence and pole electricity. Besides that,
The Guardian went farther and explained that Brown was " plays Harry Potter on-screen TV during the
collision ". According to a statement that is spoken by the Board of Safety Transportation National: the accident
was produced by the " failure of the driver truck to yield the right of way and a lack of attention of the driver's
car because it was too reliant on automation of the vehicle ". By because of it, accidents Brown strengthens
AGV it provokes a lack of attention of the driver on the road.
When we are dealing with an accident, the vehicle when it relies on the ability of humans to make
decisions to avoid collisions, and if not inevitable, to crash as safe as possible. However, AGV must decide the
best way to crash. This has become a moral decision, a decision that humans cannot make in a few seconds.
With an offensive example of which is described by Well, if the AGV traveling in lane two lanes when the
vehicle else traveling to a direction that is opposite and suddenly swung to the track, the vehicle automatically
should decide how to react based program that has been defined previously. Program preset it will analyze all
alternatives to choose anyone that provokes more bit number of the injured. It is important to clarify that the
prediction is not sure because it is based on statistics and probability. In concrete, in the example it appears the
three alternatives are different: the first, to swivel to the left and off the road to avoid a collision between two
vehicles; the second, crashing into both vehicles; and third, to accelerate and pass other vehicles to avoid
falling.
As a result, we can relate this example to the Trolley Problem. In paradox philosophical explained that
there was a trolley on the outside of the control to the bottom Canada five people were tied. You stand on the
side lever that can change its direction to the train fire elsewhere only there is one person in the belt. There are
two options: do not any anything else and trolleys that killed five people, or pull the lever so that the trolley
that killed one person. Which decision is the most ethical? It is a question that the same was asked by
programmers AGV alone when they know of a situation like that.

2.2.3 Effect of location, Operation, & Maintenance Against AGV

Factors to be kept in mind during the AGV design are shown in Table 1. These factors are divided into
two categories, one based on literature review and the other on the basis of opinion skills, both from academia
and industry.

Table 1: Factor affecting the designing of AGV [27].

NO FACTORS

1 Number of AGVs required

2 Volume of production

3 Traffic management technique

4 Layouts of AGV tracks in the industry

5 AGVs path layout

6 Positioning of idle vehicles

7 Battery management

8 Failure management

9 Decision regarding provision of control zone

10 Capacity of buffer for the vehicle

11 Queue capacity of each machine

12 Investment according to current and future

manufacturing requirement
13 Shortest path route

14 Poor communication

15 Speed of AGVs
 16 Difficulty in changing organisation culture

17 Level of preventative maintenance

18 Poor information system

19 Poor selection of process sequence

20 Long period of implementation

21 Economical problem

22 Lack of standard procedure

23 Proper training

- Explanation regarding the effect of maintenance factors on AGV

Hiking flow is the path guided that remained where the vehicle can do trips to a variety of point -making
and delivery charges. To avoid a situation of collision and roads clogged, the necessary management and traffic.
To prevent from the collision of physical and barriers in line, sensors mounted on an AGV [28]. Discuss
concepts for obstacle avoidance. Control zone is the type of the traffic of the most popular and much-used
management [29]. Vehicles traveling from one zone to zone more and only one vehicle allowed at one time in
a zone. The order in which jobs are supposed to be handled by vehicles can be determined based on routing
information. That's the number of AGV that is required is the sum of the total time of the trip was loaded and
empty and while waiting for the AGV within the period of time occupied, divided by the time the AGV is
available during the period it. Number of AGV that is enough with the speed that both should be available to
transport the load at a time that is appropriate. Total round-trip that is done every vehicle hour and the number
of total trips home to go can be used to estimate the amount of total required vehicle [30].

3. FUTURE OPPORTUNITIES
In modern manufacturing systems, AGVs have become an integral part of MHSs. [31] because of high
flexibility of AGVs, the guide path can be easily modified to respond to any changes in the FMS where routine
changes are inevitable. In order to avoid collisions among each other and complete their tasks, AGVs need to
be coordinated along the roadmap itself [32]. Graphs of the several layers are used for searching the path. A
large number of papers have been presented in the literature related to AGV issues [33]. Tested a new method
in a warehouse environment which combines modern technology in electronics and mathematical science. A
number of researchers have discussed AGVs and various issues related to it in their literature but there are
some gaps in the literature.

- The most important gap in the literature is the adaptation and implementation of FMS and AGVs in
developing countries where labor is very cheap and easily available.
- In literature, assumptions include mostly flat floors and the assumed availability of infrastructure that
is provided to support vehicle guidance.
- There are few review papers on multi-load AGVs. Multi-load vehicles are expensive, but can lead to
a substantial throughput increase, depending on the quality of the scheduling system.
- The most machine scheduling studies either assume infinite number of transporters for delivering the
materials or neglect the transportation time [34].
- The majority of researches which are available in the FMS literature consider the material processing
through workstations only and assume uninterrupted possibility of AGVs and processing machines.
Obviously, most of these assumptions are not realistic for an AGV based system [35].
- It is worth noting that modelling the traffic in a multivehicle system is still an open problem, that has
been investigated by several research groups [36].
 The performance of the overall system is greatly influenced by the guide path layout since it has direct
impact on the travel time, on the installation costs, on the complexity of the control system software and
efficiency of vehicle dispatching and scheduling. Researchers in the last few years have paid much attention
in the AGV path design problem. To formulate various AGV path design problems, integer or mixed integer
programming models have been used and many of them were solved by branch-and-bound based methods.
The AGV guide path layout problem was first proposed. Problems layout lines guide the AGV is the first
proposed [37]. Discussed the problem of designing of guide path layout and routing algorithm for AGV along
the bidirectional path to minimize the total distance travelled [38].
This research fills the research gap regarding the reliability and maintenance of multi-AGV systems.
Methodologies have been developed to model the multi- AGV System design, operation, and maintenance
strategy. The work period ahead will extend the model to incorporate the relevant other activities of
maintenance, such as maintenance predictive. Also, the methodology that is described in the paper can be
upgraded to a model that is more substantial and the system AGV is more complex. This can be achieved by
dividing the system into small basic operating elements. By investigating the system layout structure elements
of the base and the interactions in between them, the simulation of a system that is complex to do. Moreover,
the approach that was developed in the paper is also able to easily adjusted with a model of the maintenance
of a fleet of vehicles other, such as a bus or truck.

4. CALCULATION
The MHS is the backbone of a FMS. The performance of the overall system is greatly influenced by the guide
path layout since it has direct impact on the travel time. On the installation costs, on the complexity of the
control system software and efficiency of vehicle dispatching and scheduling. There are various factors which
could affect in the layout design, operation, and maintenance implementation of AGVs in a manufacturing
system therefore, it is very much necessary to foresee the problems associated with it. The researchers may be
prompted to identify some other issues, which may be significant in addressing these factors. The
manufacturing managers can get an insight of these factors and understand their relative importance and
interdependencies and try to overcome these factors which affect the performance of AGVs. The objective of
this study was to develop an approach to design an optimal flow path for AGVS. Hence the aim of the work
presented in this paper is to demonstrate the advantages of applying this evaluation of layout design, operation,
and maintenance of multi system automated guided vehicles (AGV) technique to this area. Also, the technique
has been adapted in this work and a novel approach is adopted using different types of nets which interact to
provide the overall system availability. The results obtain from this study can help the management in making
strategic and tactical decisions relating to process layout, operations, and maintenance improvement for
improving the efficiency and performance of a manufacturing system in view of changing market conditions.
The results can be verified by simulating the entire problem. Simulation would take in account the travel of
unloaded vehicles, buffering, congestion and other control aspects, it would give a more complete picture of
the system. Formulating the programs takes less time than building a simulation model and could be solved in
less time. So, using the mathematical programming a layout may be generated and then tested using the
simulation. The environments in which the approach is best suited are flexible ones, i.e., more specifically
where, optimal flow path may change as the material flow intensity in from-to chart changes. Assuming that
the departmental layout design, operation and maintenance other assumptions do will increase, constraints of
the problem remain the same. All that will change is the coefficients of the objective function.

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