Decision-Making Framework For AMR Fleet Size In Manufacturing Environments

Industry 4.0 is transforming manufacturing environments, with robotics being a key technology that enhances various capabilities. The flexibility of Autonomous Mobile Robots has led to the rise of multi-robot systems in industrial settings. Considering the high cost of these robots, it is essential to determine the best fit of number and type before making any major investments. Simulation and modeling are valuable decision-support tools, allowing the simulation of different setups to address robot fleet sizing issues. This paper introduces a decision-support framework that combines a fleet manager software stack with the FlexSim simulator, helping decision-makers determine the most suitable mobile robots fleet size tailored to their needs. Unlike previous approaches, the developed solution integrates the same real robot coordination software in both simulation and actual deployment, ensuring that tested scenarios accurately reflect real-world conditions. A case study was conducted to evaluate the framework, involving multiple tasks of loading and unloading materials within a warehouse. Five different scenarios with varying fleet sizes were simulated, and their performances assessed. The analysis concluded that, for the case study under consideration, a fleet of three robots was the most suitable, considering relevant key performance indicators. The results confirmed that the developed solution is an effective alternative for addressing the problem and represents a novel technology with no prior state-of-the-art equivalents.