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Use Case

FORKLIFT TRACKING

Maximize operational efficiency with precise, real-time forklift location tracking and prevent incidents with RTLS-powered collision avoidance systems. Optimize turnover, picking, shipping, lead time, and forklift utilization while eliminating costly downtime.

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Track and Monitor Forklifts in Real-Time

Real-time tracking of forklifts and other vehicles, like tugger trains and hand pallet trucks, is vital for enhancing logistics and production efficiency. Inpixon's forklift tracking solution ensures precise location accuracy, reaching up to +/- 40 cm with UWB RTLS technology. This boosts visibility, efficiency, and profitability and enhances workplace safety.

The solution facilitates comprehensive process tracking, offering a holistic overview of vehicle positions in the warehouse, factory, or yard. Easily integrate real-time location data into EWM, ERP, MES, and other systems. Further replace manual workflows with smart IIoT and RTLS technology, including vehicle auto-ID and automatic process triggering. 

Our UWB-based collision avoidance system provides advanced warnings,  and offers optional automatic braking, along with setting and enforcing speed limits within controlled areas.

Additionally, achieve faster throughput through rack-level guiding. This approach empowers logistics and production managers to optimize fleet resources, reduce man-hours wastage, and proactively prevent accidents.

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Benefits of RTLS for Forklift Tracking

  • Operational Efficiency and Visibility
    • Comprehensive tracking instantly provides an overview of intralogistics processes, allowing you to see who is doing what task at a glance.
    • Reduced search times and key performance indicators (throughput rate, inventory turnover rate, error rate, downtimes, utilization rate) lead to streamlined work processes.
    • Identification of optimization potential enables sustainable cost reduction.
  • Rack-Level Guidance and Scannerless Goods Transportation
    • Scannerless transportation and guidance to the rack level improve throughput times.
    • Warning functions contribute to error-free operations.
    • Maximized productivity with streamlined routes and processes, coupled with enhanced inventory accuracy.
  • Safety Enhancement and Cost-Effective Tracking
    • UWB-based collision avoidance ensures safety during forklift operations.
    • Focusing on forklift tracking over individual pallets minimizes expenses.
    • Geofences, sensors, and automatic triggers minimize risks, reducing potential damages and enhancing overall safety.

Example Uses for
Forklift Tracking

  • Visualize forklift locations in real-time.

    See the entire facility on a map and visualize vehicle digital twins moving about. Correlate vehicle, personnel, and goods locations for complete operational awareness.
  • Search and find.


    Instantly locate vehicles in various states, track goods via forklifts, and promptly manage inactive vehicles with operator alerts or task assignments.
  • Automate dispatch orders.

    The system dispatches orders to forklift operators dynamically based on location, task priority, and operational efficiency.
  • Track loaded goods.


    Automatically log goods during pickup using the forklift tracking system, eliminating manual scanning and maintaining a continuous track of goods throughout their journey in the facility.
  • Guide routes, alert when wrong routes are taken.
    Optimize driver routes by offering the shortest or fastest options, while issuing timely warnings for deviations or unauthorized access to routes or misplacement of goods in the wrong rack.
  • Watch movements and monitor progress.

    Monitor the movement of critical assets and generate real-time material flow reports for better operational management.
  • Collision avoidance.


    Boost safety with proximity alerts featuring lights, horns, wristband vibrations, and auto-braking to prevent accidents. Enforce speed limits in controlled zones for enhanced safety.
  • Get alerts/notifications.

    Receive notifications for forklift movements across different zones, load status changes, and other key events.
  • Identify bottlenecks.


    Pinpoint route and pathway congestion points that are impacting workflow, productivity, and safety.
  • Monitor equipment utilization.

    Track and manage forklift usage and maintenance to proactively schedule repairs and minimize downtime.
  • Measure equipment effectiveness.

    Analyze patterns of forklift usage, including travel distance, idle time, productivity, loaded vs unloaded time, and more.
  • Monitor and manage energy usage.

    Track electric forklift usage times to optimize charging schedules and reduce energy costs.
  • Enhance worker performance.

    Use tracking data to assess operator safety compliance, providing targeted training and feedback.

How Forklift Tracking Works with Inpixon RTLS

Inpixon RTLS employs UWB technology for precise (±40cm) or long-range chirp (CSS) real-time asset tracking. Each tracked vehicle has a tag transmitting signals to anchors on ceilings, which calculate real-time positions with high accuracy. The derived location data powers diverse asset-tracking applications, enhancing productivity, safety, and overall business results in Industry 4.0 environments.

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Forklift location being tracked while RFID-enabled pallet communicates with smart warehouse shelves.

Forklift Tracking Building Blocks

Your solution is unique to your business. That’s why we’ve built our comprehensive platform to be flexible and dynamic, allowing you to leverage multiple types of technologies to power a wide array of use cases, build tailored location-aware hardware and solutions, and seamlessly integrate with asset management applications, IoT platforms, and other external systems to solve your unique problems.
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    RTLS Platform & ERP/WMS Integration

    Inpixon's RTLS platform ensures real-time forklift tracking, boosting supply chain visibility. This technology-agnostic solution automates processes, providing actionable insights for strategic decisions and optimizing overall equipment effectiveness. Seamlessly integrating data from various RTLS technologies and IoT sources into ERP, MES, and WMS systems, it streamlines operations for efficient forklift tracking and operational excellence.

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    VehicleTAG+

    The VehicleTAG+ is a cost-effective industrial tag designed for tracking forklifts, autonomous industrial vehicles, and AGVs. This multisensor tag enables real-time tracking using UWB, GPS, and optional LiDAR technology. It provides seamless indoor and outdoor tracking and includes integrated sensors for temperature, humidity, movements, and shocks.

    With enhanced connectivity through CAN-Bus, Wi-Fi, BLE, and optional sensors like fork RFID readers, the VehicleTAG+ is well-suited for various industrial applications. Engineered to optimize overall equipment effectiveness (OEE), it enhances quality and flexibility in production and intralogistics. Easy to install on material transport vehicles, it is hardwired to a power source for consistent operation.

  • UWB-RTLS-NODE

    RTLS Node UWB

    The RTLS NODE UWB stands out as a fixed antenna system designed for real-time indoor positioning, particularly suited for Gabelstapler tracking. This robust UWB positioning antenna provides precise ±40 cm location accuracy and includes an internal accelerometer and temperature sensor.

    As a low-maintenance and cost-efficient RTLS anchor, the RTLS NODE UWB offers remarkable scalability for indoor applications. It seamlessly complements GPS or chirp technologies. With its rugged and waterproof housing, this solution is a durable choice for demanding industrial deployments, ensuring reliable and accurate forklift tracking in various environments.

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    Ultrasonic

    Ultrasonic sensors can help determine the exact position of the forklift and load. This is particularly useful for performing precise lifting and lowering maneuvers and increasing load handling efficiency.

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    RFID

    Warehouse management: RFID tags can be attached to storage materials, pallets, or containers. This enables efficient warehouse management, as the forklift truck can automatically read the RFID tags and transfer the data to the WMS. This makes it easier to track inventory, manage stock, and avoid errors in the movement of goods.

    Load identification: RFID can be used to verify the identity of loaded materials or products. This is particularly useful to ensure that the forklift lifts the correct load and transports it to the intended location.

    Automation of processes: Automated processes can be implemented using RFID. This includes, for example, the automatic recognition of loads during storage and retrieval and triggering actions such as updating inventory data or opening gates.

    Access control: RFID can control access to certain areas or functions of the forklift. This ensures that only authorized personnel can perform certain actions.
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    LiDAR

    Obstacle Avoidance and Navigation: LiDAR sensors enable precise mapping of the forklift's surroundings in real-time. This promotes effective obstacle avoidance, preventing collisions with objects, other vehicles, or personnel within the warehouse environment. The forklift can navigate through the facility with enhanced safety and efficiency.

    Load Positioning and Handling: LiDAR aids in accurate load detection and positioning. By emitting laser beams to measure distances, it ensures that the forklift aligns perfectly with the load, streamlining the loading and unloading processes. This feature is particularly beneficial when dealing with diverse load sizes and shapes.

    Autonomous Operations: LiDAR facilitates the implementation of autonomous processes in forklift operations. The technology allows for the creation of detailed maps of the warehouse, enabling the forklift to operate autonomously, identify storage locations, and execute tasks such as material retrieval and transportation without human intervention.

    Improved Safety: LiDAR enhances overall safety by providing real-time data on the forklift's surroundings. It can detect the presence of pedestrians or obstacles in the forklift's path, triggering automatic responses to prevent accidents. This ensures a safer working environment for both operators and other personnel in the warehouse.

    Dynamic Path Planning: LiDAR enables dynamic path planning for forklifts, optimizing routes based on real-time conditions within the warehouse. This not only enhances efficiency but also reduces energy consumption and minimizes wear and tear on the equipment.
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    Sensors

    Temperature and humidity sensors: These sensors monitor the ambient conditions, especially when sensitive goods are transported. They help ensure that storage conditions are maintained and products are not affected by extreme temperatures or humidity.

    Speed sensors: These sensors monitor the speed of the forklift truck to ensure that it complies with the applicable speed limits. This contributes to safety in the workplace.

    Acceleration sensors: These sensors measure the acceleration of the forklift. They are useful for accurately tracking vehicle movements and can assist in monitoring abrupt braking or acceleration.

    Acceleration and Rotational Speed Sensor (IMU): An IMU sensor is a device that measures acceleration of the forklift using an accelerometer and rotational speed using a gyroscope in order to detect changes in the speed, direction, and rotational movements of an object.
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    Collision Warnings

    Collision warning lights: If an obstacle is detected, warning lights on the forklift can be activated to alert the driver. These lights are often positioned to be visible, either on the mast of the forklift or in other highly visible locations.

    Acoustic warning signals: In addition to lights, acoustic signals, such as warning horns or beeps, can also be activated to draw the driver's attention to the obstacle.

Forklift Tracking FAQs

  • What is RTLS, and how does it benefit intralogistics?

    RTLS (Real-Time Locating System) is a technology that enables the real-time location of objects, vehicles, or people. By using technologies such as UWB, Chirp, BLE, or others, RTLS offers precise location determination. In intralogistics, this brings numerous benefits, including improved visibility and accuracy, increased efficiency in route planning and stock movements, optimized inventory management, accurate tracking of assets, higher order accuracy, increased labor productivity as well as improved security and data analysis for continuous optimization.

  • How easy is it to implement RTLS for forklift management?

    Implementing RTLS for forklift management requires some initial setup and configuration, but the process is straightforward and can typically be completed within a few days. The system requires the installation of readers at key location points, attaching tags to forklifts, and configuring the central rtls platform. In most cases, the system can be integrated with other warehouse and yard management solutions, further streamlining operations.

  • What is the ROI of implementing RTLS for forklift management?

    Implementing RTLS for forklift management provides a significant ROI, with most intralogistics achieving payback within 12-24 months. The system provides real-time data that enables managers to optimize resource utilization, reduce operating costs, and increase worker safety. By reducing idle time and improving the accuracy of inventory data, the system can help achieve significant cost savings while improving overall efficiency. Additionally, the system helps enhance worker safety, reducing the risk of accidents and injuries that can result in costly downtime and legal liability.

  • How often is the location data of the forklifts updated, and how accurate is the positioning?

    The truck location data is usually updated constantly [e.g., 30 seconds]. The exact frequency depends on the specific settings and requirements of the forklift tracking use case. The position is determined with high accuracy by integrating, for example, UWB with up to 10-50 cm or Chirp technology 1-2m.

  • How can we ensure the forklift tracking system is seamlessly integrated with other WMS?

    Seamless integration of the forklift tracking system with other systems is achieved through standardized interfaces and protocols, particularly REST API. Extensive testing is carried out before implementation to ensure compatibility and interoperability with existing systems such as ERP, WMS, and others.

Forklift Tracking Resources
IoT

Key Trends for Smart Factories & Intralogistics in 2024

16 minute read | January 22, 2024
IoT

How to Optimize Warehouse Processes with RTLS

14 minute read | November 16, 2022
IoT

5 Key Steps for Building a Smart Warehouse

13 minute read | August 23, 2022
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