Hybrid plant logistics: 
the perfect interplay of manned fleets and AGV control

Plant logistics is constantly developing - automation plays a central role in this. Companies are faced with the challenge of making their internal logistics more efficient, flexible and sustainable. One promising solution: hybrid fleets consisting of automated guided vehicles (AGVs) and manned vehicles. But how can these two types of transport be optimally coordinated? The answer lies in an intelligent control system that networks and seamlessly integrates all transport resources.

Hybrid fleets for plant logistics

Hybrid fleets in plant logistics are mixed fleets of manned and automated (AGVs) vehicles that use a shared order pool.

A typical scenario: In a production plant, numerous material movements between incoming goods, warehouse, production and outgoing goods have to be coordinated on a daily basis. A hybrid fleet is used: AGVs take on standardized, repetitive transport tasks within single halls, while manned vehicles are used for more complex or unpredictable transports. A central control system enables flexible and dynamic operation of all transport resources and ensures optimum utilization of the existing plant infrastructure.

Why is joint management crucial?

In dynamic plant logistics, control systems must be able to react flexibly to unforeseeable events such as traffic jams, technical disruptions or last-minute order changes. A modern control system must therefore not only be able to allocate transport orders efficiently, but also to optimize them in real time. This reduces empty runs, improves resource utilisation and ensures smooth plant logistics.

Without a comprehensive control system, AGVs and manned vehicles remain stand-alone solutions that do not work together optimally. An intelligent intralogistics management system such as SYNCROTESS, allows dynamic order allocation, where transport orders are assigned according to vehicle type, availability and priority. The system also calculates the most efficient routes to prevent bottlenecks or collisions. Multi-stage transport chains, such as transport across several halls with AGVs and subsequent handover to manned vehicles, are handled automatically by the transport control system.

The combination of automation, intelligent control and manned vehicles creates an optimum balance between standardization and flexibility. Companies benefit from better planning and resource utilisation. At the same time, they can react more quickly to unforeseen events, such as short-term bottlenecks or disruptions in the material flow.

Conclusion: Hybrid as a bridge technology

Hybrid fleets are far more than a temporary solution - they represent a sustainable and scalable strategy for plant logistics. The combination of AGVs and manned vehicles enables companies to progressively automate without sacrificing the necessary flexibility. Transport processes can be made more efficient, transparent and economical through centralized control.

Companies that rely on integrated control at an early stage secure long-term competitive advantages and lay the foundations for future-proof intralogistics.

To what extent do you utilize the potential of hybrid fleets?