Autonomous Guided Vehicles AGVs
Automated Guided Vehicles (AGVs) are transforming manufacturing, warehousing, and logistics by improving efficiency and reducing manual handling.
However, deploying AGVs introduces unique safety, compliance, and operational challenges that must be addressed to protect people, equipment, and productivity.
At Cobots and Machinery Safety, we specialise in guiding organisations through the safe and legally compliant implementation of AGV systems.
Common Challenges with AGV / AMR Deployment
Integrating AGVs into a live environment is not as simple as installing the technology. Key issues we help our clients overcome include:
Risk of Human–Machine Interaction
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AGVs share space with pedestrians, forklifts, and other equipment, creating potential collision hazards if routes and zones are not properly planned and safeguarded.
Compliance with Machinery Safety Standards
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AGVs fall under the Machinery Directive (CE/UKCA) and must meet requirements such as EN ISO 3691-4 for driverless industrial trucks, as well as PUWER obligations for safe use.
Emergency & Control Systems
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Faulty emergency stops, inadequate safety-rated control systems, or poorly configured sensors can lead to uncontrolled movement or unexpected stops.
Environment & Infrastructure
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Floor markings, lighting, and network connectivity all influence AGV performance and must be carefully assessed to maintain safety and reliability.
AGV & AMR Safety Assessments – Ensuring Safe and Compliant Autonomous Operations
Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) are transforming material handling and logistics across factories, warehouses, and production environments. But with increased autonomy comes greater responsibility — ensuring that every system operates safely around people and other machinery.
Our AGV and AMR safety assessment services help you identify hazards, verify compliance with ISO 3691-4, and demonstrate full conformity with PUWER, Machinery Directive, and HSE safety requirements.
What Is an AGV / AMR Safety Assessment?
An AGV or AMR safety assessment evaluates the safety and compliance of autonomous or semi-autonomous mobile robot systems. These machines interact directly with people, equipment, and infrastructure — meaning risk management is crucial to avoid collisions, entrapment, or unsafe operation.
During the assessment, we review:
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Vehicle navigation and control systems (laser, magnetic, vision-based)
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Speed, braking, and obstacle detection functions
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Safety-rated laser scanners, bumpers, and emergency stops
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Functional safety systems and software validation
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Compliance with ISO 3691-4, ISO 13849, and IEC 62061
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PUWER and Machinery Regulation (UKCA / CE) requirements
Following the inspection, you’ll receive a detailed safety audit report highlighting non-conformities, risk levels, and recommendations for corrective actions — helping you maintain a safe and legally compliant fleet.
Who Should Carry Out AGV Safety Assessments?
AGV and AMR risk assessments must be performed by competent safety professionals with expertise in automation, robotics, and machinery safety standards.
At Cobots and Machinery Safety our assessors are experienced engineers specialising in autonomous vehicle safety, functional safety validation, and PUWER compliance. We work with manufacturers, system integrators, and end users to provide independent AGV and AMR compliance audits that combine technical accuracy with practical, actionable advice.
Whether you operate a single vehicle or a full automated fleet, we’ll help ensure your systems meet every applicable HSE and international safety requirement.
When Should AGVs Be Risk Assessed?
A safety assessment for automated guided vehicles should be conducted:
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Before initial deployment of any AGV or AMR system
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After software or navigation updates that affect performance
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Following incidents, near misses, or layout changes in the workspace
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Periodically, as part of scheduled PUWER inspections or safety audits
Regular assessments ensure your autonomous vehicles continue to operate safely as environments evolve — preventing collisions, downtime, and costly compliance issues.
Key Standards and Legal Requirements
AGVs and AMRs must comply with a range of UK and international standards, including:
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ISO 3691-4 – Safety requirements for driverless industrial trucks and their systems
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ISO 13849 / IEC 62061 – Functional safety of control systems
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PUWER 1998 – Safe use of work equipment
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Machinery Directive (2006/42/EC) or UK Supply of Machinery (Safety) Regulations 2008
Our assessments confirm compliance across all relevant standards, ensuring your system is safe, validated, and ready for certification or audit.
Safe, Efficient, and Legally Compliant Automation
AGVs and AMRs can dramatically improve efficiency — but only when they operate safely in shared environments. Our AGV and AMR safety assessment services give you peace of mind that your autonomous systems are compliant, reliable, and fully optimised for real-world conditions.
Book your AGV / AMR Safety Assessment today to ensure compliance with ISO 3691-4, PUWER, and HSE safety requirements.
Our Expertise
Our consultants provide end-to-end AGV safety services, ensuring your deployment meets legal requirements and operational best practices:
Safety Risk Assessments
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Conducting comprehensive risk assessments in accordance with EN ISO 12100 and EN ISO 3691-4, identifying hazards such as collision risk, unexpected movement, and energy isolation.
Route & Zone Design
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Designing safe travel paths, speed restrictions, and pedestrian interfaces to minimise risk of contact or obstruction.
Compliance Verification
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Reviewing manufacturer documentation, CE/UKCA marking, and control systems to ensure your AGVs meet all relevant machinery safety standards.
Operator & Maintenance Training
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Delivering tailored training for staff to safely operate, monitor, and maintain AGVs within a shared workspace.
Commissioning Support
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Assisting during installation and acceptance testing to verify emergency stops, sensors, and control system safety before the AGVs go live.
Why Choose Cobots and Machinery Safety?
Proven Safety Expertise
In-depth knowledge of AGV technology, risk assessment, and machinery regulations.
Regulatory Compliance Assurance
From CE marking to EN ISO 3691-4 and PUWER requirements, we help you navigate complex regulations
Seamless Integration & Support
Ensuring your AGVs operate smoothly within your existing processes with minimal disruption.
Ensure your AGVs are safe, compliant, and ready to perform
Schedule your expert safety assessment today.
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