Forklifts weren’t designed to be the backbone of long-distance pallet movement.

Yet in most facilities, forklifts have become exactly that and the result shows up everywhere:

Rising accidents

Rising wear and tear

Rising labor hours with no value attached

Rising operational drag

When forklifts are used for hauling long distances, you’re paying for movement, not productivity. This is the spaghetti map problem.

A spaghetti map reveals every path your forklift takes during a shift. The picture is always the same: looping routes, doubled-back paths, pedestrian crossings, and aisles choked with non-value-added movement.

That wasted motion comes with a hard cost:

Drivers spending half their shift in transit

High-value forklifts burned out on long-haul work

Safety risk multiplied across every aisle

Unpredictability that slows every downstream station

Our Autonomous Pallet Mover

Forklifts work in dedicated zones, where they perform high-value maneuvers. Cyngn’s DriveMod Autonomous Tugger connects those zones on a fixed, efficient route — a simple back-and-forth shuttle.

The impact is immediate:

Fewer forklift miles and a dramatic drop in travel time

Higher throughput without adding labor

A safer floor with fewer high-risk forklift crossings

A predictable pulse of material movement tied to task time

This is Lean Manufacturing applied to the movement of goods.

What's the purpose of the trip?

Restock several work areas from storage, over and over

Keep a production line fed with parts and materials

Move finished goods off the line to staging or the warehouse

Shuttle work-in-progress between cells or process steps

What can be seen on the route?

Tuggable carts

Palletized loads

Both carts and pallets

Other, a mix of stuff

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How often does this trip run?

Constantly — all shift long

Several times an hour

A handful of times a day

It varies day to day

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Biggest problem with this route?

People stuck hauling instead of higher-value work

Too much traffic on the floor

Inconsistent or unpredictable timing

It just eats hours

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Last step, get your results!

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Calculating your results

Calculating your results

Calculating your results

Calculating your results

Unlock Productivity You’ve Already Paid For

Your highest-paid operators shouldn’t spend their day “commuting” between departments. With our autonomous tugger handling the long-distance pallet transport:

Forklift drivers stay in their seat and do the value-added work

Workers stop chasing materials and stay at their stations

Supervisors shift from chaos to consistency.

When movement becomes predictable, everything downstream gets faster.

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Dramatic reduction in forklift travel

Reduced risk and costs of incidents

Reduced maintenance costs

Higher throughput with fewer touches

Stable flow between production areas

Every Deployment Begins with a Practical Optimization Consultation

Our team maps your facility, identifies spaghetti hot spots, and redesigns the long-haul flow around the dumbbell model. With our ROI guarantee, we align with your business goals by ensuring our autonomous tuggers meet your payback target.

We’ve found that not automating costs up to 4x more than investing in an Autonomous DriveMod Tugger.

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Turn Forklift Miles Into Measurable Efficiency Gains

Our Autonomous Tuggers deliver substantial ROI for facilities with:

High forklift mileage

Long distances between receiving, production, and storage

Pain around labor shortages or absenteeism

Increasing accident rates

Variability in material arrival times

If you have a spaghetti map, you have waste.

Before adopting Cyngn’s autonomous tugger, we relied on a substantial manual effort—about 200 forklift trips per week—to handle pallet deliveries between two buildings. Now, we move four pallets at a time, a 4x increase in efficiency, and our staff is freed up for more value added processes.

Dave Hoover VP of Technical Services, U.S Continental Chemical Manufacturer