Automated Guided Vehicle and AMR Safety

• Pedestrians struck, pinned, or trapped by an AGV or mobile robot
• Loads shifting, falling, or blocking sensors and warning devices
• Blind corners, doorways, intersections, and mixed vehicle traffic
• Workers assuming sensors will always detect and stop for them
• Manual recovery or towing performed without proper control
• Battery charging, damaged batteries, or electrical faults

Automated guided vehicles and autonomous mobile robots move materials without a driver, but they share aisles, intersections, workstations, and production areas with people and other equipment.

Workers should understand the designated routes, crossings, right-of-way rules, warning lights, sounds, speed zones, and restricted areas used by the system. Shortcuts through robot paths can create unexpected conflicts.

Sensors and control systems help the vehicle detect obstacles, but they are not a substitute for pedestrian awareness. Clothing, reflective surfaces, load position, debris, tight clearances, or unusual movement may affect detection and stopping.

Pedestrians should avoid stepping in front of a moving unit, walking closely beside it, riding on it, or entering a pinch point between the vehicle and racks, walls, machines, doors, or other equipment.

Loads should remain stable, within capacity, and positioned so they do not block sensors, lights, or travel clearance. A shifted pallet, projecting material, or unstable container can strike workers even when the vehicle itself clears the route.

Intersections, blind corners, doorways, elevators, docks, and mixed forklift areas require added attention. Mirrors, barriers, markings, signals, and traffic controls should be maintained and obeyed.

Only trained and authorized personnel should reset, recover, tow, manually move, or service a stopped vehicle. Workers should not push, pull, climb on, or reach beneath an AGV or AMR to restore production.

Route changes, construction, temporary storage, spills, damaged floors, poor lighting, and new workstations should be reported because the automated system may not respond safely to an environment that differs from its approved layout.

• Use designated pedestrian routes and crossings.
• Do not assume sensors will detect every person or object.
• Stay out of pinch points beside moving vehicles.
• Keep loads stable and clear of sensors and warning devices.
• Use extra caution at intersections and blind corners.
• Allow only trained personnel to reset, recover, or tow units.
• Report route obstructions and facility changes promptly.

• Where do AGV or AMR routes cross pedestrian or forklift traffic?
• What warning signals and right-of-way rules apply?
• Could a load block sensors or extend beyond the vehicle?
• Where are the fixed-object pinch points along the route?
• Who is authorized to recover or service a stopped unit?