Published: July 2025

Technology is changing the way warehouses and industrial sites work. One big change is the growing use of autonomous forklifts, also known as AGVs (Automated Guided Vehicles) or AMRs (Autonomous Mobile Robots). These machines can move materials on their own, without a driver. They promise more safety, lower costs, and greater efficiency. But how do they compare to traditional manned forklifts?

If you’re a supervisor or equipment manager, it’s important to understand the pros and cons of each. This guide breaks down the key differences so you can make smart decisions about your equipment and operations.

What Are They?

Manned Forklifts:
These are forklifts driven by trained workers. There are different types, such as counterbalance trucks, reach trucks, and pallet jacks. Manned forklifts are flexible and can handle unexpected tasks easily.

Autonomous Forklifts:
These forklifts use sensors, cameras, and computers to move around and do jobs without a driver. They can follow set paths or adjust to their surroundings using AI. Papé Material Handling goes into further detail how OTTO AMRs operate.

Side-by-Side Comparison

Flexibility

• Manned Forklifts: Highly adaptable. Operators can quickly respond to changing conditions or unexpected situations.
• Autonomous Forklifts: Limited adaptability. Best for structured, repetitive tasks in stable environments.

Safety

• Manned Forklifts: Safe when used by well-trained drivers. Allows for real-time problem solving.
• Autonomous Forklifts: Equipped with sensors to avoid accidents, but can struggle in cluttered or unpredictable spaces.

Initial Cost

• Manned Forklifts: Lower upfront investment. Easier to integrate into existing operations.
• Autonomous Forklifts: Higher initial cost due to advanced technology and infrastructure needs.

Operating Cost

• Manned Forklifts: Includes wages, training, and certification. Offers oversight and flexibility.
• Autonomous Forklifts: Lower labor costs but requires specialized maintenance and system updates.

Productivity

• Manned Forklifts: Productivity can be high, especially in dynamic settings where quick thinking is required.
• Autonomous Forklifts: Reliable and consistent output but less capable of handling unexpected challenges.

Maintenance

• Manned Forklifts: Straightforward mechanical upkeep, widely supported by service providers.
• Autonomous Forklifts: Requires both mechanical servicing and ongoing technical support for software and sensors.

Integration

• Manned Forklifts: Compatible with most existing workflows and infrastructure.
• Autonomous Forklifts: May need significant upgrades to warehouse layout and employee retraining.

Safety and Legal Requirements

Safety is one of the biggest concerns in material handling. According to OSHA, forklift accidents cause about 85 deaths and 34,900 serious injuries in the U.S. every year (OSHA). Many of these accidents are caused by human mistakes.

Autonomous forklifts are designed to reduce these risks. They use obstacle detection, automatic brakes, and planned routes to avoid problems. Still, they can have trouble in messy or dark areas.

For compliance, manned forklifts must meet OSHA standard 1910.178. Autonomous forklifts must follow other rules like ANSI/ITSDF B56.5. Both types need regular checks to stay in compliance.

Where Each Type Works Best

Manned Forklifts Are Best When:

• You have a lot of variety in loads and tasks
• The layout changes often
• You're working outdoors or on uneven ground

Autonomous Forklifts Are Best When:

• You move pallets the same way every day
• Your inventory flow is predictable
• You need to limit people in certain areas (like cold storage or hazardous zones)

Cost and Value Over Time

Autonomous forklifts can save money over time, even though they cost more upfront. They reduce labor costs, cause fewer accidents, and keep working longer hours. Walmart has already begun integrating automated lifts into their distribution center warehouses. According to Supply Chain Dive, Walmart’s facility associates have already seen a leap in progress and “higher output” since implementing FoxBot automated lifts.

Many companies benefit most by using both types. You can keep manned forklifts for complicated jobs and use autonomous ones for repetitive work.

What Makes It Hard to Switch?

Switching to autonomous forklifts takes planning. You may need to:

• Add new tech to your warehouse (like sensors and digital maps)
• Train staff to work with or monitor the robots
• Protect your systems from cybersecurity risks

Even with manned forklifts, you still need to invest in training and make sure workers stay certified.

FAQs

Q: Can autonomous forklifts replace human drivers?
A: Not completely. They’re good at simple, repeated tasks but can’t handle sudden changes like a human can.

Q: Do autonomous forklifts follow OSHA rules?
A: They follow different safety standards like ANSI/ITSDF B56.5. Make sure you check for both OSHA and ANSI compliance.

Q: How can I tell if my facility is ready for autonomous forklifts?
A: Try using them in one area first. If they work well and don’t cause problems, you can expand their use.

Q: Do autonomous forklifts still need maintenance?
A: Yes. They need regular mechanical care and software updates by trained technicians.

Q: What makes it hard to start using autonomous forklifts?
A: The biggest challenges are high upfront costs and the changes needed in your facility.

Final Thoughts

Manned and autonomous forklifts both have their strengths. To choose the best option, think about your goals, your team, and your budget. Often, a mix of both gives you the most benefits in safety, productivity, and savings.

Choosing the right setup now can help your facility stay competitive and ready for future demands.