As UK warehouses face rising demand, labour shortages, and growing pressure to operate more efficiently, many businesses are turning to a mixed fleet approach to strike the right balance between automation and manual operations. By combining traditional forklifts with automated guided vehicles (AGVs), a mixed fleet can significantly reduce downtime and deliver a strong, measurable return on investment (ROI).
If you’re exploring warehouse automation for the first time, this guide will break down why mixed fleets are becoming the go-to choice for forward-thinking operators.
Before looking at the solution, it helps to understand the problem. Warehouse downtime is often caused by:
For many UK operations, fully automating everything isn’t practical or cost-effective. But introducing the right level of automation, in the right places, can dramatically reduce these downtime triggers.
A mixed fleet combines the best of human-operated equipment (for flexibility and complex tasks) with AGVs (for repetitive, high-volume movement). This hybrid approach keeps warehouses running smoothly even when demand fluctuates or labour availability is limited.
1. AGVs Eliminate Repetitive Delays
AGVs excel in tasks such as pallet transport, cross-docking, or long-distance warehouse movements. These repetitive tasks are a major source of delays when handled manually, particularly during busy periods.
By offloading these predictable jobs to AGVs, your workforce can focus on more complex, high-value activities — reducing bottlenecks and keeping operations flowing.
2. Predictable, Safe, 24/7 Operation
Advanced AGVs from providers like Rocla AGV Solutions are designed for continuous use. They operate with consistent speed, precise navigation, and built-in safety systems. This means fewer stoppages due to accidents, breaks, or shift gaps; a key advantage in warehouses aiming for round-the-clock productivity.
3. Smarter Fleet Management Prevents Traffic Congestion
Modern automation platforms integrate both AGVs and manually operated forklifts, creating optimised routing to avoid congestion points. Fleet control software coordinates movements in real time, preventing unnecessary delays and reducing the risk of collisions or blocked aisles.
4. Reduced Equipment Damage and Maintenance Interruptions
A significant portion of warehouse downtime comes from vehicle damage or unplanned repairs. AGVs operate with millimetre-level accuracy and consistent behaviour, dramatically reducing wear-and-tear on racking, pallets and the forklifts themselves.
A mixed fleet reduces dependency on labour for repetitive transport. Rather than replacing people, AGVs take over the high-volume tasks, allowing teams to focus on jobs requiring judgement. This improves output per labour hour.
2. Faster Material Flow = Higher Throughput
When AGVs work alongside forklift trucks, pallets move faster and more consistently through the operation. More throughput, without extra headcount or additional shifts, directly boosts profitability.
3. Reduced Product and Infrastructure Damage
AGVs dramatically cut the costs associated with damaged stock, equipment and racking. These savings accumulate rapidly, particularly in high-volume warehouses with tight margins.
4. Scalability Without Large Upfront Investment
Mixed fleet solutions offer gradual automation. Businesses can start with a few AGVs and expand over time — perfect for UK warehouses looking to modernise without major capital expenditure. This step-by-step model spreads costs and makes ROI more predictable.
A mixed fleet is often the best fit for warehouses that:
Many warehouse operators realise that a fully automated warehouse is not always the optimal or most cost-effective solution. Mixed fleet gives you the benefits of automation where it makes sense and leaves the rest in human hands.
For many UK operations, going “fully automated” is unnecessary. A mixed fleet delivers the core benefits of automation — reliability, efficiency, safety and reduced downtime — while preserving the agility of a human workforce.
With providers like Mitsubishi Forklift Trucks and Rocla AGV demonstrating just how seamless mixed-fleet operations can be, more warehouses are discovering that automation doesn’t need to be all-or-nothing.
It simply needs to be optimal.
If you're interested in discussing what options are available for your business, get in touch via the Greenline on 0845 3713048 or complete our contact form.