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Goods-to-person AGV fleet — 320 robots, 3.2× pick rate
Warehousing & Logistics•2025•Texas, USA

Goods-to-person AGV fleet — 320 robots, 3.2× pick rate

Designed and commissioned a 320-AGV goods-to-person system across 240,000 sq ft, replacing two-level mezzanine pick.

Client
Confidential — 3PL Operator
Location
Texas, USA
Capabilities
Turnkey Line Build · Robotics Integration · Process Engineering
320
AGVs deployed
3.2×
Lines per hour per associate
12 wk
Full ramp

The challenge

The 3PL was forecasting 3× volume growth from a single retail client over 18 months. The existing pick-to-light mezzanine could not flex, hiring was a constraint, and the building lease prevented new mezzanine permits.

What we built

We designed an AGV-driven goods-to-person layout with 38 pick stations, integrated fleet management with the existing WMS via REST, and ran a phased install over 6 weeks alongside live operations. SLAM-based localization let us avoid floor magnets.

Key equipment

  • Geek+ S20 / P40 AGVs ×320
  • Honeywell pick stations
  • Cisco industrial Wi-Fi 6
  • Custom WMS integration layer

From the floor

Illustrative image — representative of project scope; customer-identifying details have been removed.

Goods-to-person AGV fleet — 320 robots, 3.2× pick rate — 1
Goods-to-person AGV fleet — 320 robots, 3.2× pick rate — 2
Goods-to-person AGV fleet — 320 robots, 3.2× pick rate — 3
Goods-to-person AGV fleet — 320 robots, 3.2× pick rate — 4

Results

Ramped to full fleet in 12 weeks. Lines per hour per associate moved from 78 to 250, peak-season hiring need dropped 60%, and the client signed a 5-year extension citing the new throughput.

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