PFNonwovens launches a contest to name their new A.Celli by Smartlogistix AGVs
In this interview, Tracy Schooley, HR Director at PFNonwovens, shares how a simple internal contest can be a powerful tool to drive engagement and humanize automation.
What inspired the idea of launching an internal contest to name the AGVs?
The idea came from a simple but powerful intention: to make the introduction of AGVs something shared by the entire company. Rather than presenting them as just another technological upgrade, we saw an opportunity to turn them into something people could relate to. Launching a naming contest felt like a natural way to involve everyone, giving employees a chance to leave their personal mark on the project and feel part of this new chapter in our operations.
How did employees react when the contest was first announced?
The reaction was immediately positive. Employees really appreciated the chance to take part in something creative and a bit different from their everyday routines. The idea of naming the AGVs sparked curiosity and enthusiasm, and the added element of a small prize made it even more engaging. But beyond that, what stood out was the genuine excitement of seeing their ideas potentially come to life within the plant.
How did the contest unfold?
We made sure the initiative was visible and accessible to everyone across the facility. Several internal announcements were shared to keep the momentum high and encourage participation. To make the process simple and inclusive, drop boxes were placed in different areas of the plant so that all employees, regardless of their role or department, could easily submit their proposals. This helped create a sense of anticipation as ideas started coming in from all corners of the organization.
Did any proposal particularly surprise or amuse you?
What truly stood out was the overall level of creativity: each proposal brought something unique, from clever wordplay to more imaginative or humorous ideas. Rather than a single entry, it was the collective creativity that impressed us the most. The contest revealed a side of our employees that doesn’t always emerge in day-to-day operations, making the whole experience both entertaining and genuinely rewarding.
Do you think this initiative helped reduce the “distance” between people and automation?
Absolutely. From the very beginning, we wanted to ensure that the introduction of AGVs was not perceived as something distant or disruptive, but rather as a shared evolution of our processes. Alongside the contest, we invested time in explaining how the AGVs work and how they would support and improve daily operations. The naming initiative played a key role in this effort: it fostered a sense of familiarity, transparency and inclusion. The strong participation from employees across all departments clearly showed that people felt involved and engaged, helping bridge the gap between technology and the human side of our organization.
A methodological approach to ROI calculation
The correct evaluation of ROI is not limited to the comparison between initial investment and direct benefits, but requires the definition of a financial model that considers the entire duration of the project and all the variables at play.
Fundamental quantitative KPIs
To translate qualitative benefits into clear financial indicators, it is essential to define a series of quantifiable Key Performance Indicators (KPIs):
Operating costs (OpEX)
- Cost per unit handled: calculation based on the total cost of labor and energy divided by the number of units managed, comparing manual and automated systems.
- Maintenance: comparative analysis between costs and productivity impact of a predictive maintenance model (typical for automation) compared to traditional corrective maintenance.
- Energy Consumption: specific measurement of consumption (kWh/cycle) of AGVs/AMRs and automated systems, compared to the consumption of traditional internal combustion or electric forklifts.
Productivity
- Hourly throughput: increase in the number of units or pallets handled per hour, as a result of continuous 24/7 operation.
- Average order cycle time: reduction of the average time needed to complete an order, from receipt to shipment.
- OEE (Overall Equipment Effectiveness): increase in overall plant efficiency, measuring availability, performance and quality.
Space optimization
- Volumetric capacity: increase in storage capacity per cubic meter, possible thanks to the implementation of vertical warehouses and shuttles that maximize density.
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Footprint reduction: less need to physically expand the warehouse, with consequent savings on real estate and energy costs.
Data accuracy and traceability
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Inventory errors: drastic reduction in the percentage of inventory errors (e.g. from 2-3% to a value below 0.1%), thanks to the precision of automated systems.
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Picking error reduction: Fewer errors in item picking, with a direct impact on reducing costs from returns and management expenses.
Workplace safety
- Accidents and associated costs: decrease in the number of workplace accidents (e.g. per million hours worked) and reduction of insurance costs and operational downtime.
Financial models: beyond the basic formula
The evaluation of long-term CapEx projects requires rigorous financial modeling to avoid underestimating costs and overestimating benefits.
- NPV (Net Present Value): calculates the present value of future cash flows generated by the project, discounting them at a discount rate. A project is financially valid if the NPV is positive, indicating that future benefits exceed the initial investment.
- IRR (Internal Rate of Return): represents the discount rate that zeros the NPV. A project is acceptable if the IRR is higher than the company's cost of capital, signaling good intrinsic profitability of the investment.
- TCO (Total Cost of Ownership): a comprehensive TCO analysis is fundamental. It includes not only the initial CapEx (hardware, software, infrastructure), but also recurring operational costs (OpEx) over a time horizon of 5-10 years. These costs include maintenance, energy consumption, software licenses, technical assistance and upgrade costs, often overlooked in superficial analyses.

ROI analysis phases
An effective evaluation is structured in a methodological process that ranges from data collection to continuous analysis.
Phase 1: Baseline & Data acquisition
This phase consists of creating a precise and scientific snapshot of the current situation. Monitoring with IoT sensors on existing machinery, time-and-motion studies and extraction of historical data from WMS, ERP and other business systems are crucial. The objective is to quantify the costs, times and errors of manual processes to have a solid comparison base.
Integration with OT and WMS systems is guaranteed by Smart_Logistix.
Phase 2: Technical-economic modeling and simulation
In this phase the financial model is built and assumptions are validated. Through industrial simulation software (such as FlexSim or AnyLogic), it is possible to create a digital twin of the warehouse and test automated scenarios. This allows accurate estimation of throughput, cycle times and impact on flows, before committing capital. The DCF (Discounted Cash Flow) model is enriched with sensitivity analysis to test the project's robustness against variations in key variables such as energy cost, interest rates or project duration.
Phase 3: Post-implementation monitoring
After installation, the verification phase is crucial to validate predictions. Through real-time analytics, telematic data collected from robots, WMS/WCS and SCADA systems are compared with baseline KPIs and initial projections. Business Intelligence (BI) dashboards play a fundamental role in providing a clear vision of performance and identifying continuous optimization opportunities.
Recommended operational strategy
Economic justification must be accompanied by an operational strategy that guarantees its success.
Modular planning and retrofitting
For an existing infrastructure (brownfield), the ideal solution is not a complete revolution, but a planned evolution. A modular and scalable approach allows automation to be introduced gradually, starting from areas with a faster Payback Period. The integration of mobile robots in existing warehouses, or retrofitting of traditional systems, reduces risks and minimizes operational downtime, making the transition efficient.
Personnel involvement
Automation is not only a technological challenge, but also a cultural one. Personnel must be involved from the early phases of the project, through transparent communication and a continuous training program. The requalification of operators for new roles (e.g. supervision, maintenance) not only promotes acceptance, but transforms personnel into a strategic resource for managing new technologies.
Common errors to avoid
Field experience teaches that some recurring errors can undermine ROI analysis:
- Considering only initial CapEx, neglecting TCO: ignoring recurring costs such as software licenses, predictive maintenance and energy consumption can compromise the validity of the calculation.
- Overestimating benefits: basing projections on overly optimistic scenarios, without considering possible delays or the personnel learning curve, can lead to disappointing results.
- Ignoring the key role of change management: failure to manage the impact on personnel can cause resistance that translates into low productivity and failure to achieve objectives.
Conclusion
Evaluating ROI in automation investments is a multidisciplinary process that goes beyond pure economic calculations. For a C-level, engineers and specialists audience, a rigorous approach that integrates advanced financial methodologies, detailed TCO analysis, and the use of simulation and analytics tools is the key to making solid strategic decisions.
Companies that adopt this perspective will not only obtain clear and validated economic justification, but will also equip themselves with an operational roadmap to maximize the value of investment over time, strengthening their competitive position in a continuously evolving market.
Do you want to build a custom financial model, compare AGV/AMR solutions and estimate the real ROI of your infrastructure? Contact us: our experts are ready to guide you with cutting-edge tools and expertise.