How long should an AGV system actually last? The answer isn’t simply a number. How often the vehicle runs, how it was designed, battery selection, preventive maintenance, documentation, and even whether the right spare parts are sitting on the shelf can all play a role. In this episode of Getting Traction with Mobile Robots, David Moses, Engineering Manager at America in Motion, breaks down the practical decisions that can help manufacturers get more life and value out of their AGV systems. In this episode, we'll cover: - Why preventive maintenance beats reactive maintenance - How operating hours affect maintenance schedules and expected life - What wheels, bearings, gearboxes, ball screws, and other components can tell you before a failure - The tradeoffs between lead-acid and lithium batteries - Why maintenance documentation matters across shifts - How spare-parts planning can reduce downtime - How design decisions made before an AGV hits the plant floor can influence its longevity One of the simplest takeaways from the conversation? Treat an AGV a lot like your car: take care of what you already have instead of waiting for something to break. Timestamps 00:00 – Introduction 01:29 – How long should an AGV system last? 03:26 – What helps an AGV reach a 15–20 year service life? 04:39 – Maintenance practices that influence longevity 05:37 – How do you know when maintenance is due? 06:37 – Who should be responsible for AGV maintenance? 09:22 – Battery management and system health 10:44 – Lead-acid vs. lithium batteries 12:21 – How small maintenance issues become expensive problems 14:44 – How AGV design decisions affect longevity 16:52 – Why maintenance documentation matters 18:31 – The big takeaway: plan ahead and keep critical parts on hand 🎧 Listen the full conversation to hear David Moses explain how manufacturers can think beyond installation and plan for the AGV’s entire working life. Interested in AGVs for your operation? 🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction 📊 Start Planning Your AGV System Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system 🤝 Talk to an AGV Expert Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation Listen to the full episode! Apple Podcasts: https://podcasts.apple.com/us/podcast/getting-traction-with-mobile-robots/id6790501808 Spotify: https://open.spotify.com/show/033OTi8LIsYJ25spt9mByj Follow America In Motion LinkedIn: / america-in-motion Facebook: / aimagvs #AGV #MobileRobots #PreventiveMaintenance #ManufacturingAutomation #MaterialHandling #IndustrialAutomation

Implementing AGVs and mobile robots doesn't have to mean production chaos. In Episode 6 of Getting Traction with Mobile Robots, host Emily Pallikan sits down with Chase Eklund, Product Development Manager at America in Motion, to discuss one of the biggest concerns manufacturers have when considering automation: How do you implement AGVs without disrupting production? Chase shares a behind-the-scenes look at what a successful AGV rollout actually involves, from facility surveys and virtual testing to phased implementation strategies and customer collaboration. He explains how modern automation projects minimize downtime through simulation, validation, scheduling, and careful planning before a single vehicle arrives on-site. Whether you're exploring automation for the first time or looking to expand an existing system, this episode provides a practical look at how AGV implementations are designed to protect production schedules while delivering long-term operational gains. In this episode, you'll learn: ✅ Common misconceptions about AGV implementation ✅ How phased rollouts reduce production risk ✅ Why simulation and testing are critical before deployment ✅ The role scheduling plays in successful automation projects ✅ How AGVs integrate with existing automation systems ✅ Why short-term downtime often leads to long-term gains ✅ Real examples of AGV systems still running after 15+ years Episode Timestamps: 01:41 Episode overview: implementing AGVs without disrupting production 03:07 The biggest production schedule concerns manufacturers have 04:04 The AGV implementation process explained 05:30 Minimizing downtime through planning and scheduling 07:22 Working through bugs before deployment 10:09 Does every AGV implementation require a shutdown? 11:03 Why AGV ROI often outweighs short-term disruption 11:42 What a phased rollout looks like in a real facility 13:19 Automation as an entire journey 13:57 The hidden complexity behind AGV systems 14:57 The orchestra analogy: automation working together 15:21 Common mistakes companies make during AGV rollouts 16:27 Why scheduling is critical to implementation success 17:43 Real-world example of a tightly planned installation window 19:55 The backstage work required before automation goes live 21:14 Planning for unforeseen delays and contingencies 22:44 Advice for manufacturers worried about production disruption 23:33 Why invest in AGVs in the first place? 24:15 Customer success story: AGV system operating for 18 years 26:47 Final advice for companies considering automation 27:30 Closing thoughts and additional resources Interested in AGVs for your operation? 🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction 📊 Start Planning Your AGV System Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system 🤝 Talk to an AGV Expert Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation Listen to the full episode! Apple Podcasts: https://podcasts.apple.com/us/podcast/getting-traction-with-mobile-robots/id6790501808 Spotify: https://open.spotify.com/show/033OTi8LIsYJ25spt9mByj #AGV #Automation #Manufacturing #MobileRobots #MaterialHandling #Industry40

Implementing Automated Guided Vehicles (AGVs) is about more than technology. Even the most advanced system can struggle if the workforce isn't prepared for the change. In this episode of Getting Traction with Mobile Robots, Emily sits down with Chase Eklund, Product Development Manager at America in Motion, to discuss what happens when AGVs arrive on the plant floor, how employees typically react, and what companies can do to create a smooth transition. From addressing safety concerns to effective training strategies, they share practical insights for leaders preparing their teams for automation. Key Topics Covered: - Why AGVs often create a "shell shock" reaction when first introduced - Common employee concerns about safety and autonomous equipment - How AGV safety systems work in shared environments - Best practices for workforce training and education - The importance of hands-on demonstrations and real-world examples - How facility operations may need to adapt for AGV success - The role of an internal "AGV Champion" - Tips for preparing employees before implementation begins - Why awareness and communication are critical to long-term adoption Episode Timestamps: 00:00 Introduction: Why workforce preparation matters 02:35 First reactions employees have when AGVs arrive 03:41 Understanding common safety concerns 06:04 Building trust through demonstrations and hands-on interaction 07:30 The mindset shift required for successful AGV adoption 08:40 AGV training vs. forklift training 10:20 Who should be trained on an AGV system? 11:50 The importance of an AGV Champion 14:45 Preparing your workforce before AGVs arrive 15:42 Creating an open learning environment around automation 16:37 Key takeaways: safety, awareness, and building confidence 18:03 Comparing AGVs to other technology advancements 19:12 Closing thoughts Interested in AGVs for your operation? 🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction 📊 Start Planning Your AGV System Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system 🤝 Talk to an AGV Expert Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation Follow America In Motion LinkedIn: https://www.linkedin.com/company/america-in-motion/ Facebook: https://www.facebook.com/AIMAGVs/ YouTube: https://www.youtube.com/channel/UCwtZWaJOw-9YWzkuC0T048w

How do AGVs fit into a larger automation system, and who should be responsible for making everything work together? In this episode of Getting Traction with Mobile Robots, Emily Pallikan sits down with Terri Blasius, Vice President and Co-founder of America In Motion, to explore the role AGVs play in connecting conveyors, robot cells, warehouse software, doors, and other automation technologies. They discuss the different levels of integration, when an AGV provider should act as the integrator, and why understanding integration ownership early can prevent costly project delays. The conversation also highlights one of the biggest obstacles in automation projects: IT. From networking and security requirements to remote access and system communications, Terri shares practical lessons from real-world deployments and explains why involving IT from the beginning is critical to a successful implementation. If you're evaluating or planning an automation project, this conversation will help you understand integration ownership, avoid common pitfalls, and bring the right stakeholders into the process from day one. Key topics: - Why networking and communication are usually the hardest part of integration - OPC tags and an OPC server as the central translation layer for most automation systems - How a central OPC hub can read signals like package presence and share them across devices - Why AGV projects often need a mix of OPC, database connections, APIs, web services, and sometimes legacy flat files - The three integration levels - How contract ownership affects who can actually direct robot, conveyor, or cell vendors - Why AGVs are often seen as the natural integrator because they move between all the other systems - The importance of early customer education about who should own integration - Remote access as a practical support solution - Common support problems such as bad OPC tags, blocked ports after Windows updates, and vehicle tuning issues - The value of retraining and documentation when customer turnover happens after installation Timestamps: 00:00 Introduction 02:10 Role AGVs play in integration 02:45 OPC tags and the central communication hub 04:53 Choosing the right integration method 06:05 Why AGVs companies are often a natural integrator 07:12 Explaining integration roles to customers 09:26 Three levels of integration projects 11:47 Integrating for future and beyond 13:00 How being integrator can give you greater control 14:13 Why networking and IT are the real hurdle 15:14 Get IT involved early or pay for it later 16:40 Retraining after turnover and keeping documentation ready 17:13 Remote access can make or break support 18:06 Troubleshooting bad tags, blocked ports, and tuning 19:18 How data moves from warehouse systems to AGVs 21:25 Reusing tools across different integration setups 22:08 The biggest takeaway: IT first, then integration 23:19 Knowing your integration level helps you choose partners Interested in AGVs for your operation? 🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction 📊 Start Planning Your AGV System Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system 🤝 Talk to an AGV Expert Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation Listen to the full episode! Apple Podcasts: https://podcasts.apple.com/us/podcast/getting-traction-with-mobile-robots/id6790501808 Spotify: https://open.spotify.com/show/033OTi8LIsYJ25spt9mByj Follow America In Motion LinkedIn: https://www.linkedin.com/company/america-in-motion/ Facebook: https://www.facebook.com/AIMAGVs/

The vehicles move material, but software is what connects people, processes, and automation across your operation. In Episode 3 of Getting Traction with Mobile Robots, host Emily Pallikan sits down with Terri Blasius, Co-Owner and Executive Vice President of America In Motion, to discuss one of the most overlooked aspects of AGV deployments: software integration. From simple call-button applications to complex ERP and WMS integrations, Terri explains how software serves as the coordination layer that helps conveyors, robot cells, warehouse systems, and mobile robots work together. The discussion also covers open versus closed software, the risks of vendor lock-in, and why involving IT early can help set automation projects up for long-term success. Whether you're evaluating your first AGV system or planning for future growth, this episode will help you better understand the software decisions that can impact flexibility, scalability, and ownership for years to come. Key Takeaways: ✅ AGV software acts as the coordination layer between equipment, systems, and workflows. ✅ Understanding the difference between open software, closed software, and open-source software is critical when evaluating automation providers. ✅ Vendor lock-in can limit flexibility and create challenges as operations evolve. ✅ Integration requirements can range from simple vehicle controls to complex ERP and WMS communication. ✅ More manufacturers are building internal automation expertise and taking greater ownership of their systems. ✅ Involving IT early helps avoid integration headaches later in the project. ✅ Data visibility, dashboards, and system insights are becoming increasingly valuable for operations teams. ✅ Scalable software creates a foundation that can support future growth and changing business needs. Timestamps: 02:03 —The role software plays in AGV integration 03:01 — What is “open” software and the benefits 03:56 — Limitations of closed software 05:06 — Why most AGV users don't need source code 06:20 — Three levels of integration ownership 07:01 — Creating automation teams for AGV success 08:31 — Examples of integration roles 10:59 — Having control over your AGV system 11:54 — IT and software support 14:24 — Scalability of software for future growth 18:25 — Picking a vendor for best AGV software 13:42 — Bring IT in early 15:00 — Supporting AGV systems over time 17:30 — A full workflow example from order to execution 20:42 — What teams often overlook 20:28 — Final insights: AGV software should adapt to you and your operations Interested in AGVs for your operation? 🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction 📊 Start Planning Your AGV System Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system 🤝 Talk to an AGV Expert Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation Listen to the full episode! Apple Podcasts: https://podcasts.apple.com/us/podcast/getting-traction-with-mobile-robots/id6790501808 Spotify: https://open.spotify.com/show/033OTi8LIsYJ25spt9mByj Follow America In Motion LinkedIn: https://www.linkedin.com/company/america-in-motion Facebook: https://www.facebook.com/AIMAGVs/ #MobileRobots #AGV #Automation #SystemIntegration #Interoperability #Manufacturing #IndustrialAutomation #Industry40 #WarehouseAutomation #DigitalTransformation

When companies evaluate automation, labor savings usually get all the attention. But some of the most significant costs in an operation come from somewhere else entirely: damages. In this episode of Getting Traction with Mobile Robots, host Emily Pallikan sits down with Tommy Hessler, CEO and cofounder of @americainmotion to discuss the hidden costs associated with manual material handling and why many manufacturers underestimate their impact. From damaged products and pallets to facility repairs, rework, safety incidents, and operational disruptions, damage often becomes accepted as "the cost of doing business." Tommy explains how AGVs change that mindset by bringing consistency, predictability, and greater visibility to material handling operations. If you're evaluating automation solely through the lens of labor reduction, you may be missing a major part of the ROI equation. Key Topics Covered: - The often-overlooked costs associated with damages in manual versus automated material handling - How damages accumulate over time and impact overall ROI - The role of automation in reducing damage variability and improving safety - The importance of comprehensive cost analysis beyond labor savings - Practical methods for quantifying damages through throughput analysis and presumptive calculations - Industry-specific examples, including textiles and packaging, illustrating damage mitigation - The future of AGVs in enhancing environmental and safety standards - Tips for engaging financial decision-makers with damage-related data Timestamps: 00:00 - Introduction to damages in AGV systems and why it matters 01:36 - Set the stage: Costs of damages in manual vs. automated handling 05:04 - The significant value of transported loads and damage impact 06:17 - The difficulty of measuring damages in practice 04:52 - Visualizing total cost breakdown and payback periods 07:14 - Lessons from textile industry leak detection and measurement 08:28 - The role of automation in handling damages more consistently 09:29 - Damage variability caused by human drivers and how automation reduces it 10:56 - Environmental benefits: Noise reduction and pollution considerations 12:19 - Enhancing safety with programmed speed controls and pedestrian gates 13:00 - The misconception that AGVs will replace human jobs; instead, they free workers for smarter tasks 13:34 - Complete control over AGV behavior and operational safety protocols 13:54 - Innovative approaches: Flexible plant layouts with non-linear AGV operations 14:41 - Industry pioneers: Volvo’s early autonomous vehicle experiments 16:10 - Practical advice for quantifying damages and assessing ROI 17:07 - Simple calculations to estimate damage costs over time 18:01 - Risks of ignoring damages: Misjudged payback and missed improvement opportunities 18:51 - Final insights: Talking to financial decision-makers and making data-driven choices Interested in AGVs for your operation? 🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction 📊 Start Planning Your AGV System Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system 🤝 Talk to an AGV Expert Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation Listen to the full episode! Apple Podcasts: https://podcasts.apple.com/us/podcast/getting-traction-with-mobile-robots/id6790501808 Spotify: https://open.spotify.com/show/033OTi8LIsYJ25spt9mByj Follow America In Motion LinkedIn: https://www.linkedin.com/company/america-in-motion Facebook: https://www.facebook.com/AIMAGVs/

What Does an AGV System Really Cost? The price of an AGV is only part of the story. In this first episode of Getting Traction with Mobile Robots host Emily Pallikan sits down with Tommy Hessler, CEO and co-founder of @americainmotion to break down the real costs behind a successful AGV deployment. Learn the difference between vehicle cost and system cost, the major cost categories buyers should expect, why quotes can vary dramatically from one supplier to another, and how to evaluate long-term value beyond the initial purchase price. Whether you're exploring automation for the first time or planning your next project, this episode will help you make more informed AGV investment decisions. Key Topics Covered: - The difference between AGVs and AGV systems, including infrastructure needs - The major cost drivers: hardware, intelligence, safety, and safety systems - The importance of scalability and flexibility for future growth - Cost implications of choosing Chinese-made vs. American-made AGVs - Total cost of ownership including maintenance, support, and battery systems - Critical role of planning, flow analysis, and simulation to avoid overinvesting - The value of an AGV champion in your organization to ensure successful adoption - Long-term benefits: efficiency gains, damage reduction, and safety improvements Timestamps: 00:00 - Introduction 01:20 - Welcome Tommy Hessler 02:00 - Why understanding AGV costs is crucial for automation success 02:55 - Differentiating between AGVs and AGV systems 05:53 - Various infrastructure components of AGV system (fleet manager, tracking, etc.) 07:31 - Cost ranges for simple vs. complex, highly integrated AGV systems 09:34 - Battery types, management, and their effect on ownership costs 12:15 - Considering Chinese-made vs. U.S.-made AGVs in your purchasing decision 13:55 - The importance of support, software, and system flexibility 14:40 - Planning for growth, retrofit potential, and long-term adaptability 18:47 - The differences in buying an AGV system versus a car and the buying experience 19:26 - The importance of virtual planning and simulation before implementation 22:04 - Total cost of ownership, including maintenance and IT support 24:32 - What companies should be thinking about financially when investing in AGVs 27:42 - Differences between AGVs and forklifts, why simulation matters and proper training 30:07 - Key questions for financial planning and ROI estimation 30:54 - Final remarks Ready to take the next step? 🎙️ Explore More Podcast Episodes: https://www.weareaim.com/getting-traction 📊 Start Planning Your AGV System Estimate fleet size, pricing, and ROI with our AGV Planning Tool: https://www.weareaim.com/plan-agv-system 🤝 Talk to an AGV Expert Get answers to your questions and discuss your application: https://www.weareaim.com/agv-consultation 🔔 Subscribe for more great content: @americainmotion Listen to this episode on the go! 🍎 Apple Podcasts: https://podcasts.apple.com/us/podcast/getting-traction-with-mobile-robots/id6790501808 🟢 Spotify: https://open.spotify.com/show/033OTi8LIsYJ25spt9mByj Follow America In Motion LinkedIn: https://www.linkedin.com/company/america-in-motion/ Facebook: https://www.facebook.com/AIMAGVs/

Introducing Getting Traction with Mobile Robots, a new podcast from America In Motion designed to help manufacturers navigate the world of AGV and mobile robot automation with confidence. Each episode features practical conversations with AGV experts who share real-world lessons, implementation strategies, best practices, and emerging trends shaping the future of manufacturing. Whether you're exploring automation for the first time or looking to optimize an existing system, this podcast delivers actionable insights to help you make more informed decisions. Official Launch: Tuesday, July 28, 2026 New episodes every other Tuesday Subscribe now so you don't miss the first episode. 🔗 Learn more about America In Motion: https://www.weareaim.com/ 🔗 Learn more about Getting Traction: https://www.weareaim.com/getting-traction Listen & Follow ✅ Subscribe on YouTube: https://www.youtube.com/channel/UCwtZWaJOw-9YWzkuC0T048w ✅ Follow on Spotify: https://open.spotify.com/show/033OTi8LIsYJ25spt9mByj ✅ Follow on Apple Podcasts: https://podcasts.apple.com/us/podcast/getting-traction-with-mobile-robots/id6790501808 What automation topics would you like us to cover on future episodes? Leave a comment below and subscribe to stay up to date on the latest conversations in AGVs, mobile robotics, and manufacturing automation. #GettingTractionPodcast #MobileRobots #AGV #ManufacturingAutomation #IndustrialAutomation