AGV / AMR ROI Calculator
Forklift-to-AGV conversion business case model
Operations
Forklift operators / shift
5
Shifts / day
2
Working days / year
254
Pallets / day
500
Labor
Avg fully-burdened rate
$85K
Labor reduction %
60%
Residual FTE override
3
Wage inflation / yr
3.0%
Equipment & Hardware
AGV unit cost
$240K
AGV-to-fork ratio
1.2×
Charger unit cost
$20K
Charger ratio (AGVs : charger)
2.5
Annual AGV maintenance %
8.0%
Annual SW subscription
$25K
Project Cost Factors
WES software %
15%
Commissioning %
18%
Integration %
12%
Contingency %
20%
Facility size (sq ft)
250K
Concrete cost / sq ft
$8
Floor prep % of area
15%
Electrical cost / charger
$12K
Financial Assumptions
Discount rate (WACC)
7.5%
Evaluation period (years)
5
Investment Breakdown
Cash flow over evaluation period
Annual savings (inflation-adj)
Future-state OpEx
Cumulative cash flow
Current vs future state cost
Payback sensitivity (±10% scenarios)