Autonomous Forklift Implementation Guide
Deploying autonomous forklifts is a structured process — not a science experiment. With over 50 deployments across Australian warehouses, we've refined a proven implementation methodology that gets your robots operational in 4-12 weeks, with minimal disruption to existing operations.
Implementation Timeline
| Phase | Duration | Activities |
|---|---|---|
| 1. Assessment | 1-2 weeks | Site survey, workflow analysis, ROI modelling, solution design |
| 2. Design | 1-2 weeks | Fleet selection, path planning, charging locations, integration spec |
| 3. Procurement | 2-4 weeks | Robot ordering, charging infrastructure, network preparation |
| 4. Installation | 1-2 weeks | Robot delivery, LIDAR mapping, charging station setup |
| 5. Integration | 1-3 weeks | WMS connection, task workflow configuration, fleet management setup |
| 6. Testing | 1-2 weeks | Path testing, safety validation, performance tuning, staff training |
| 7. Go-Live | 1-2 weeks | Supervised operation, optimisation, sign-off |
Site Requirements
Floor Condition
Standard warehouse floors (sealed concrete, epoxy, or resin) are suitable. Floors should be reasonably level (< 3% gradient) and free of major cracks or potholes. Most existing warehouses qualify without modification.
Aisle Dimensions
Minimum aisle width depends on the model: 1.3m for our single pallet stacker, 2.25m for slim forklifts, 3.25m for reach trucks, 3.76m for counterbalance trucks. We measure during the site survey.
Wi-Fi / 5G Coverage
Reliable wireless connectivity throughout the operating area. Wi-Fi 5 or 6 is sufficient for most deployments. We assess signal strength during the site survey and recommend AP placement if needed.
Power for Charging
Standard 3-phase power supply for charging stations. One charging point per 2-3 robots is typical, positioned at natural rest points in the workflow. Total power draw is modest — comparable to a domestic electric vehicle charger.
What Your Team Needs to Know
Autonomous forklifts work alongside your existing team. Staff training covers:
- Interaction protocols — how to work safely around autonomous robots; when they stop, how they signal, what the lights mean
- Task assignment — how to use the BrightEye tablet app to assign tasks, check status, and override when needed
- Emergency procedures — e-stop locations, how to manually move a stopped robot, fault escalation
- Basic troubleshooting — clearing minor obstructions, restarting a paused robot, checking charging status
Training is typically completed in a single day. Your team does not need robotics expertise — the system is designed for warehouse professionals, not engineers.
Go-Live Checklist
- All paths mapped and tested at operational speed
- Safety zones validated — intersections, doorways, pedestrian crossings
- WMS integration tested with live task assignment and completion
- Charging cycle verified — auto-dock, charge, return to work
- All staff trained and comfortable with interaction protocols
- Emergency procedures practiced and documented
- Performance baseline established for ongoing optimisation