Design of Automated Guided Vehicle Systems Considering the Human, Technical, and Work Organisational Subsystems

Doctoral thesis, 2025

This thesis focuses on the design of automated guided vehicle (AGV) systems. AGVs are unmanned transport vehicles that are often used in manufacturing and warehousing environments to transport materials automatically. Advances in artificial intelligence and navigational technologies for the AGVs together with an increased interest in automation has resulted in a growing number of applications of AGV systems in industry. Previous research has largely focused on the technical aspects of designing AGV systems. However, there is a risk of suboptimisation when only the technical subsystem is considered, including undermining the well-being of the employees involved in the system and failing to achieve intended performance. The need for a joint consideration of technical and social systems is emphasised by the socio-technical systems perspective, and this thesis conceives of AGV systems as comprising human, technical, and work organisational subsystems. Therefore, the purpose of this thesis is to develop knowledge to support the design of AGV systems considering the human, technical, and work organisational subsystems.

Four multiple case studies and one discrete event simulation study were conducted. The case studies focused on developing an understanding of the requirements and challenges associated with AGV system design and how they influence the design. Given the mostly technical focus in previous research, the case studies provided a suitable approach to studying the human and work organisational aspects of real industrial AGV systems. The discrete event simulation study was inspired by a real-world industrial material flow. It focused on analysing the interaction between AGV fleet size and load capacity. The research was guided both by knowledge obtained from previous research and observations of challenges faced from a practical perspective through involvement in research projects with representatives from industry that apply AGV systems in their operations.

The theoretical contribution of the thesis consists of showing the importance of the human and work organisational subsystems in AGV systems. The studies conducted for the thesis show that the work organisational subsystem requires careful consideration together with the technical subsystem, both of which are influenced by and influence the human subsystem. The work organisational subsystem is, among other things, needed to develop acceptance and create a safe work environment. This perspective of going beyond the technical subsystem contributes to the current research on AGV system design. With the limited attention given to human and work organisational subsystems in the current research literature, the practical contribution of the thesis consists of guidance for the design of AGV systems by considering these subsystems.