Warehouse AMR planning tool

AMR/AGV Calculator

AMR Fleet Calculator & AMR ROI Calculator

Estimate robot fleet size, investment, labor savings, and payback for warehouse picking, inbound receiving, and replenishment.

Comparing autonomous mobile robots (AMRs) and automated guided vehicles (AGVs)? Start your business case here. This model uses AMR-based operating assumptions; AGV fleet sizing requires validated travel, routing, and handoff rates for your specific system.

Start your exercise

No operating data has been applied.

Enter picking volume in Step 1 or pallet-movement demand in Step 6. Editable Liftian planning values are preloaded for hardware, integration, warranty maintenance, software, and error reduction.

Step 1

Enter volume

Average daily picks and busiest-day picks.

Step 2

See AMR capacity

Your AMR count is calculated at 111 picks/hour per station.

Step 3

Build your ROI

Add your labor and investment numbers for payback.

1. Daily picking volume

Start with the volume your operation ships, not a robot guess. No volume assumptions are preloaded.

Average daily picksAverage order lines or picks completed on a normal operating daypicks/dayBusiest-day picksActual or planned picks on your highest-volume operating daypicks/dayOperating hours per dayTotal hours this workflow operates across all shiftshours/dayShifts per day

2. AMR capacity recommendation

AMR-enabled stations are modeled at 111 picks per hour. Both station and AMR recommendations are calculated automatically from your volume.

Complete all four volume and schedule fields above.

Your peak hourly capacity, pick-station count, and initial AMR recommendation will appear here.

3. Current labor profile

Enter the people and productivity supporting this task today. The ROI compares your actual team with one human operator per recommended AMR-enabled pick station.

Productivity-based capacity check

Calculated after volume and current productivity are entered.

Current workers doing this task per shiftEnter the actual people assigned to this workflow on a typical shiftworkersCurrent manual picks per picker per hourYour current measured rate, including normal walking and travelpicks/hrAverage hourly wage$Benefits multiplierPreloaded at 1.30 for a 30% labor burden; edit to match your operationOperating days per yeardays

4. Investment and support

These editable Liftian planning values are preloaded. The calculated fleet automatically drives total hardware and maintenance cost.

Cost per AMRPreloaded Liftian planning value; editable$Implementation and integration feePreloaded Liftian planning value; editable$Annual hardware maintenance per AMRPreloaded at $0 because a lifetime hardware warranty is included$/AMR/yearAnnual software and supportPreloaded annual planning value; editable$/year

5. Operating benefits

Quality assumptions remain editable. Forklifts eliminated are calculated automatically at one forklift for every 10 AMRs.

Current error / mispick ratePreloaded at 5%; edit to match your operation%Average cost per error$Expected error reductionPreloaded at 5%; edit when a validated target is available%

Calculated forklift impact

— forklifts

One forklift eliminated or redeployed for every 10 recommended AMRs, rounded down.

Annual forklift lease or ownership costEnter maintenance separately below$Forklift operators redeployedForklift operator hourly wage$Annual forklift maintenanceUsed with lease cost above$

6. Inbound & replenishment capacity and ROI

Size pallet-moving AMRs separately, then add matching labor or equipment benefits before their hardware enters the combined business case.

Truckloads received per weekOptional context for inbound planning; this does not set fleet size on its owntrucks/week

How many pallets of inventory are on your floor or in your racks at any given time?Optional: enter the typical total pallets stored across your floor and racks—not daily or weekly moves or empty storage positions. For planning context only; this does not change fleet sizing or ROI.pallets

Pallet moves per weekInclude inbound receiving and replenishment moves handled by this workflowpallets/weekBusiest-day pallet movesActual or expected pallet moves on the highest-volume inbound/replenishment daypallets/dayInbound/replenishment operating hours per dayhours/dayPallet moves per AMR per hourPreloaded at 5 moves/hour; edit when the validated travel and handoff rate is availablemoves/AMR/hr

Complete weekly pallet volume, busiest-day pallet moves, and operating hours.

The editable planning benchmark starts at 5 pallet moves per AMR per hour. Your inbound and replenishment AMR recommendation will appear here.

Inbound & replenishment financial benefits

Leave wage, burden, or operating days blank to share the picking labor values. The labor estimate compares your current team with one support operator per inbound/replenishment AMR.

Current inbound/replenishment workers per shiftPeople assigned to receiving, transport, and replenishment on a typical shiftworkersInbound/replenishment hourly wageLeave blank to use the picking labor value when it is entered$Inbound/replenishment benefits multiplierLeave blank to use the picking multiplier of 1.30Inbound/replenishment operating days per yearLeave blank to use the picking schedule when it is entereddaysAdditional annual inbound equipment savingsEnter only savings not already counted under picking (for example, dedicated pallet-handling equipment). Do not repeat picking forklift savings.$/year

Inbound ROI status

Inbound hardware remains outside combined ROI

Supply a complete labor case or a measurable additional equipment saving. Capacity sizing remains available without forcing unsupported financial benefits.

How to use this estimate

Use this as an executive starting point, not a final system design. Picking capacity uses 111 picks per hour and assumes an AMR is available at the station with inventory for a human to pick. Inbound and replenishment capacity uses an editable starting benchmark of 5 pallet moves per AMR per hour and one support operator per recommended AMR for the initial labor comparison. Standalone scenarios each include shared implementation and support; the combined scenario counts those costs once. Picking forklift savings remain picking-only, while inbound equipment savings must be entered separately. Validate all results with facility layout, travel, handoff, buffering, charging, staffing, and final Liftian system design.

Need a site-specific AMR design?

We can validate peak-hour demand, product and order profiles, travel paths, pick-station utilization, and the operating fleet needed for your warehouse.

Request a custom analysis