Intralogistics & Robot-Fleet Orchestration AI Agent
Assign and sequence material-movement tasks across your fleet, watch congestion, charge and blocked routes, and escalate when the plan cannot be met — inside the zones and speed limits your engineers set.
Take movement demand from the MES, the WMS, a line call or a replenishment rule — what moves, from where, by when.
02
Read fleet state from the master control — position, load, charge, errors and the routes it has already blocked.
Reason
03
Match each move to the vehicles rated for that load, permitted in that zone, and holding the charge to finish it.
04
Sequence and prioritise against due times, the cells already waiting, and the congestion the plan is itself creating.
05
Plan charging windows inside your charge policy, so the fleet is not flat at the hour the plan needs it most.
Decide
06
Detect chokepoints, blocked routes, stranded loads and cells the priority scheme has quietly left waiting.
07
Escalate to the area supervisor when the plan cannot be met, instead of dropping the move and reporting nothing.
Out
08
Hand an ordered task list to the master control, which is what actually dispatches the vehicles.
09
Retain the demand, the fleet state read, the assignment, the escalation and every supervisor override.
→Product statement
The agent allocates and sequences tasks and nothing else. Zones, speed limits, routes and safety parameters are engineering changes with a named approver, and the vehicle's own safety system stops it whatever the plan says.
Example workflow
One move, end to end
AgentHuman
1Move requestedFrom the MES, the WMS, a kanban call, a line signal or a replenishment rule
2Fleet state readPosition, load, charge, current order, faults and the routes the master control has blocked
3Candidates matchedWhich vehicles are rated for the load, permitted in the zones on the way, and charged enough to finish
4Plan sequencedPriority, due time, the cells already waiting, chokepoint load and the charging the rest of the shift needs
No human action required
Stages 1 to 4 run without a person in the loop — reading demand, reading fleet state and sequencing all happen before anything is handed over. A move the fleet cannot meet ends that stretch on the spot.
5DecisionSplits on whether the plan can be met with the fleet as it stands
Plan can be met
Goes to the master control as an ordered task list.
Plan cannot be met
Stops with the reason and the cells at risk.
Area supervisor
Reads what cannot be met, decides what waits, what a manual truck takes, and what goes further up.
Approve plan · Re-prioritise · Escalate
Approved — handed back▼
6Task list handed overWritten to the master control as tasks — it dispatches the vehicles under its own traffic rules
7Outcome evaluatedCompletions, re-assignments, deadlocks, floor interventions, fairness across cells and charge at handover
Overrides
What the supervisor re-prioritises is counted in the evaluation.
What should not run autonomously
Human approval stays in control
Outside the boundary — human approval required8 items
Changing a zone, a route or a speed limit.
Altering any safety parameter on a vehicle.
Approving a new or re-surveyed area map.
Adding or reconfiguring a vehicle in the fleet.
Automation boundaryAgent acts unaided
✓Match a move to vehicles rated and permitted to carry it.
✓Sequence and prioritise the queue against due times and waiting cells.
✓Plan charging windows inside the charge policy your engineers set.
✓Escalate what the fleet cannot meet, with the reason and the cells at risk.
The agent writes tasks and priorities to the master control. Safety systems, zones and speed limits are out of reach.
Overriding a protective stop or a blocked route.
Returning a vehicle to service after a fault.
Opening automatic running into a manual-traffic area.
Halting or restarting the fleet.
Example output
One move, annotated
Everything the agent proposes is attached to the demand it came from and the fleet state it was planned against.
Task assignment · single moveIllustrative example
Move requested
Called by
Due by
Assigned to
Confidence
Zones and speed
Full pallet, weld cell 3 to despatch
MES replenishment rule
14:20
Tugger 4, east aisle route
91%
Unchanged — set on the vehicle
As receivedThe demand as the MES called it, and the fleet state the master control reported.
Evidence usedLive fleet stateCharge to finish the moveEast aisle queue depth
Why this vehicleTugger 4 is the only free vehicle rated for that load, that zone and the distance.
ActionApprove planRe-prioritiseEscalate
What the score decidesConfidence decides whether a supervisor sees the plan first, never a vehicle's speed.
Value
Where AI adds value
The same four claims, placed at the point in the workflow where each one applies.
Where the value landsValue 01 – 04
Every movement demandMES, WMS, kanban call or replenishment rule
03Assign & sequence
Plan inside the layout you already run
Use the plant's own zone map, vehicle capabilities, priority rules and charge policy — not a generic traffic model.
01Approved path
Keep the queue moving without a radio call
Routine moves are matched, sequenced and handed over continuously, instead of being called one at a time by whoever is nearest a screen.
02Human review
Say a cell will run dry before it does
Moves the fleet cannot meet reach the area supervisor with the reason and the cells at risk, while there is still time to send a manual truck.
04Build an evidence trail
Retain the demand, the fleet state read, the assignment, the sequence, the escalation and the supervisor's override — on both paths.
Integrations
Typical integrations
Five system groups connect to the same agent, and the fleet's own control layer stays in charge of dispatch. Which of them are in scope is decided in discovery.
Fleet & traffic controlVDA 5050 · Vendor fleet managers Traffic and zone configuration
Plant systemsSAP EWM · Oracle · Opcenter MES In-house MES · Replenishment rules
Integration availability depends on the client's existing systems and API access.
Agent controls
Six layers between the model and your fleet
Each control wraps the one inside it. A plan clears every layer before it is handed over, and the vehicle's own safety system sits outside all six.
L6 · Outermost — last line of defenceInward → L1 · closest to the model
L6Rollback / safe modeFall back to the plant's standing dispatch rules if evaluation signals degrade.Roll back
L5TraceabilityRecord the demand, the fleet state, the assignment, the escalation and every override.Record
L4Supervisor approvalPriority changes and manual-traffic areas are released by a named person.Gate
L3Feasibility gateA plan that cannot be met stops and escalates instead of being handed over anyway.Escalate
L2Capability checkA move is offered only to vehicles rated for the load, permitted in the zone and charged for it.Constrain
L1Task-only scopeThe agent writes tasks and priorities. Zones, speed limits and safety parameters are out of reach.Isolate
Model corePlan proposed — vehicle, sequence, route preference, charge window and confidence
L1 – L2Keep the agent off safety and off the wrong truck
L3Decides when a person is told instead
L4 – L5Keep priority with a person, trail intact
L6Pulls automation back when signals degrade
How Nestack evaluates it
Evaluate the whole plan — not only the moves that completed.
Coverage runs the whole depth of the workflow, and every layer is cut by slice.
Surface — the task list the master control receives
Depth of coverage ▼
E1Final-output evaluationDid the assigned move complete, on the vehicle it was given to?
E2Step-level evaluationDid it read live fleet state, vehicle capability and zone permissions correctly?
E3Tool evaluationDid the task reach the master control as planned, once and only once?
E4Intervention rateHow often did a deadlock need a person to walk over and clear it?
E5Slice evaluationHow does the plan hold across areas, shifts and traffic conditions?
E6Business outcomeWere cells fed on time, and was the fleet charged at shift change?
Floor — the material that reached the cell in time
Failure modes
Where each failure originates in the agent
Seven failure modes plotted against the five stages of the agent lifecycle. None of them moves a vehicle — the master control dispatches, and the vehicle's own safety-rated detection, speed monitoring and protective stop are what stop it, whatever the plan asked for. When a plan goes wrong the area supervisor halts the fleet from the plant's own fleet stop, vehicles hold where they are with their loads, and the task record shows every move in flight, what was on it and which cell was waiting for it.
Agent lifecycleDirection of processing →
01 · Retrieval2 modes
RF-01
Stale area map
Planned on a layout or an aisle the floor has moved past.
RF-02
Manual traffic unmodelled
An aisle the plan treats as clear fills with trucks and people.
Stage readsDemand, fleet state, capability and zone permissions
02 · Reasoning2 modes
RF-03
Move the vehicle cannot make
Assigned a load, height or zone the truck is not rated for.
RF-04
Chokepoint the plan did not model
Vehicles queue and deadlock where the model saw an open aisle.
Stage plansThe assignment, the sequence, the charge window
03 · Hand-over1 mode
RF-05
Duplicate move, stranded load
The same move dispatched twice, or a load left mid-route.
Stage handsThe ordered task list, written to the master control
04 · Output1 mode
RF-06
One cell starved by priority
The scheme feeds one area well and leaves another waiting.
Stage returnsThe plan and the escalation the supervisor reads
05 · Change / Version1 mode
RF-07
Charge plan drifts off shift
A rule or calendar change leaves the fleet flat at handover.
Stage tracksModel, priority-rule, map and fleet-configuration changes
Sev-1 · a person walks into vehicle trafficSev-2 · the move fails, material sitsSev-3 · one area waits, totals look fine
The plan is only as good as the traffic it assumed
Two aisles in the same plant are not the same problem. A dedicated route with no foot traffic runs close to plan; a shared aisle on a busy shift, with manual trucks and people in it, does not. Nestack reports performance by slice, not only in total.
Slice performance — reported separately, not only in aggregateIllustrative example
Slice
Failure rate
Lift
Lift vs. threshold
Status
Mixed pedestrian and manual traffic
6.4%
3.8×
Review
Single-aisle chokepoints
4.9%
2.9×
Review
Shift change and breaks
3.1%
1.8×
Watch
Dedicated aisles, settled area
1.2%
0.7×
Normal
Bar: intervention-rate lift vs. dedicated-aisle baseline · scale 0–4.0× · tick marks 2.0×2 of 4 slices over threshold
Evidence-linked improvement
A jam someone walked in to clear becomes a planning case
Floor interventions, deadlocks and moves that could not be met come back as replays against the same aisle, the same shift and the same traffic.
Improvement cycle · five stagesSwitchback — the path turns at Improve and returns at Learn
01Detect
Re-assignments, deadlocks and floor interventions cluster on one aisle or one shift.
02Diagnose
Traced to the map read, a vehicle capability, the priority weights, or traffic nobody feeds the planner.
03Improve
Priority rules, the capability table or the charge policy change — anything touching a zone, a route or a speed limit goes to your engineers instead.
04Verify
Replayed against recorded demand and fleet state from that area, including the shift it jammed on.
05Learn
The jam is kept as a replay case, and the aisle goes into the traffic review with your safety officer.
Learn → DetectThe return edge. A change to a zone, a route or a speed limit is an engineering change — assessed and approved by a named person before a vehicle runs on it, and never made by the agent.
Typical build scope
Twelve workstreams across six weeks
The build scope read against the delivery timeline. Week structure follows the six-week plan — discovery, fleet and layout access, planning logic, evaluation, replay against recorded shifts, then supervised running and handover.
WorkstreamWeek 1Week 2Week 3Week 4Week 5Week 6
01Workflow discovery and boundary definition.
02Fleet, master-control and interface assessment.
03Zone map, routes and speed limits as built.
04Vehicle capability and load-type catalogue.
05Demand intake from MES, WMS and line calls.
06Fleet-state read and freshness checks.
07Assignment, sequencing and priority rules.
08Charge policy and shift-boundary planning.
09Escalation routing and supervisor workflow.
10Evaluation suite and recorded-shift replay.
11Congestion and deadlock replay harness.
12Observability, deployment and Agent Care handover.
12 workstreams · 6 weeks · bar shows the weeks a workstream is active — several run in parallelFinal scope and sequence confirmed in discovery
Engagement tiers
What each tier includes
Rows are the capabilities named in each tier's scope. Higher tiers include everything below them.
Capability✓ in scope · — not at this tierPilotOne area, one fleetProductionProduction fleet integrationAdvancedMulti-area / multi-vendor fleets
Introduced at Pilot
Task assignment matched to vehicle capability✓✓✓
Read-only fleet-state monitoring✓✓✓
Escalation when a plan cannot be met✓✓✓
Deadlock and congestion replay in evaluation✓✓✓
Baseline evaluation✓✓✓
Introduced at Production
Sequencing and priority rules—✓✓
Charge-window planning—✓✓
Master-control task hand-over—✓✓
Observability and evaluation—✓✓
Introduced at Advanced
Multi-area and multi-vendor fleets——✓
Enterprise controls and cross-area reporting——✓
Build priceFrom $5,000From $8,000Custom quote
Final build priceConfirmed after discovery based on fleet size and vendors in scope, the master-control interface, areas and shifts covered, priority and escalation rules and deployment requirements.
Separate from buildBuild pricing is separate from recurring Agent Care, which covers managed monitoring, evaluations, incidents and verified improvements after launch.
What we need from you
What you bring, and what we build with it
Each input maps to a piece of build scope and a week in the delivery timeline.
You bringWe build with it
01Your as-built layout, zone map and route plan→Zone map, routes and speed limits as builtWeek 1
02The fleet, and what each vehicle is rated to carry→Vehicle capability and load-type catalogueWeek 2
03Master-control access and the task interface it exposes→Fleet, master-control and interface assessmentWeek 2
04How a move gets called today, from MES, WMS or the floor→Demand intake and fleet-state freshness checksWeek 3
05Your priority rules, and which cells must never wait→Assignment, sequencing and priority rulesWeek 3
06Recorded shifts, including the ones that jammed→Evaluation suite, recorded-shift replay and deadlock harnessWeek 4
07Named area supervisors and your engineering-change approver→Escalation workflow, then supervised running on your floorWeeks 5–6
Nothing else is requiredDeployment, documentation and Agent Care handover are ours.
Delivery timeline
Four phases across six weeks
Phases are drawn over the weeks they actually occupy. Week 5 carries both the replay harness and the first shifts your supervisors run the plan on.
PhaseW1W2W3W4W5W6
DiscoveryW1
BuildW2 – W3
EvaluateW4 – W5
Pilot & LaunchW5 – W6
Week focusW1Workflow discovery, the boundary and your zone map as builtW2Fleet and master-control access, and the vehicle capability catalogueW3Demand intake, assignment, sequencing and charge-window planningW4Evaluation suite, escalation testing and slices by area and shiftW5Replay against your own recorded shifts, then supervised runningW6Your supervisors run the plan under your own engineering-change process
Reading the bandThe feasibility gate and escalation are tested in week 4, before a task list reaches your master control in week 5.
At the end of W6The plan has run on your floor under your supervisors, with zones, routes and speed limits exactly as your engineers left them, then Agent Care takes over monitoring.
DurationSix-week plan shown · typical delivery 4–6 weeks depending on scope confirmed in discovery.
Next step · Manufacturing AI agent
Build a fleet-orchestration agent around your intralogistics.
Show us your layout, your fleet and how a move gets called today. We'll replay one of your own busy shifts against your zone map and show you where the plan would have needed a person.
