As more logistics and manufacturing warehouses adopt hybrid material handling systems that combine manually operated electric forklifts and automated guided vehicles (AGVs), establishing a targeted staff training system becomes a core prerequisite to maintain smooth operation, reduce safety risks and maximize overall workflow efficiency. Different from separate training for single equipment type, the training for mixed operation scenarios needs to break the information barrier between different operation teams, and build unified cognition of the whole workflow for all relevant personnel.

The first module of the training is unified basic theory learning. All staff involved in the mixed workflow, including electric forklift operators, AGV on-site dispatchers and loading and unloading support personnel, need to master the basic operation rules of both types of equipment. For electric forklift operators, they need to be familiar with the preset driving paths, motion priority rules, and common running states of AGVs, rather than only focusing on the operation skills of their own equipment. For AGV management personnel, they also need to learn the load limit, operation blind area and conventional operation scene of electric forklifts, so that they can make reasonable scheduling plans matching the actual operation situation on site. All trainees need to pass the theory assessment before entering the practical training link, to ensure that they have a clear understanding of the basic operation specifications of the whole site.

The second module is scenario-based collaborative practical training. The training organizer builds a simulated mixed operation scene consistent with the actual production environment, which covers high-frequency interactive scenarios such as intersection of loading and unloading points, narrow passage car passing, and temporary operation area adjustment. Under the guidance of professional trainers, trainees can repeatedly practice the standardized interaction process between electric forklifts and AGVs without production pressure, confirm the unified communication signals and handling procedures when encountering abnormal conditions, such as the confirmation process when a forklift finds a parked AGV, and the standard reporting and handling steps when an AGV breaks down and stops in the middle of the passage. This link can effectively avoid unsafe behaviors such as rushing through the passage or misoperating AGVs without permission.

The third module is regular safety and emergency response drill. The training team will organize regular refresh training and assessment every month, update the operation specifications synchronously according to the adjustment of on-site workflow, and guide all staff to develop good operation habits that match the mixed working mode.