Global Manufacturer Telematics & Analytics

Powerfleet provided operational support, fleet management, and software systems that transformed safety and improved revenue for a global manufacturer. Our on-site solutions provide real-time data. This protects workers through remote vehicle monitoring, maintenance alerts, and reduced costs associated with lift truck accidents.

Additionally, telematics data contribute to proper material handling, creating a more cost-effective and risk-free environment for large-scale production. The company deployed Powerfleet’s software and hardware across five manufacturing plants, supporting over 800 vehicles of various types. They achieved millions in labour cost savings, an 80% reduction in forklift accidents, and 100% compliance with personnel safety standards.

Situation

A global manufacturer needed solutions for heavy manufacturing processes. These occurred at five separate locations and involved about 800 vehicles, including lift trucks, tow tractors, and manlifts. They needed solutions that would improve safety in material handling operations, protect workers, and reduce costs.

Task

The customer needed a system that would ensure OSHA compliance, streamline communication, and improve safety. Their primary goals were:

1. Accuracy of vehicle monitoring and accident reporting in numerous production environments, across multiple locations.
2. Reduction of lift truck accidents and risk to personnel safety due to negligence.
3. Better data for access control, employee checklists, and vehicle status reporting.

Action

Powerfleet set the industry standard for safety enforcement and efficiency in industrial vehicles and access control systems. Powerfleet implemented:

• Access control system: This system created digital records for every driver, using their existing employee ID cards. Access to training databases is granted only to employees who are both certified and authorised to operate a vehicle.
• Electronic safety lists that prioritise OSHA's top 10 industrial safety concerns and provide a repository of useful data for managers to adjust processes and quickly address issues.
• Collision detection and accident management, Powerfleet’s patented system flags impact severity and prompts management responses. This efficient system logs accidents, eliminates downtime, and reduces the number of vehicles taken out of production.

Powerfleet’s systems comply with corporate and government safety regulations. All vehicles are digitally monitored both for location and status. Drivers are accountable in their operation, which promotes safer practices.

Steps taken

Powerfleet installed software and hardware with minimal disruption to operations in each facility. These included:

• Electronic safety checklist, accessible digitally and with cloud-based storage
• Customisable electronic notifications for managers and supervisors
• Digital employee ID verification
• Patented, vehicle-mounted Powerfleet systems

Additionally, the company's leadership began using Powerfleet's Unity platform to assess its systems. This source of information provided both a baseline and immediately identifiable areas for improvement, yielding immediate action items for low-performing sites. They reduced waste and optimised operations to maximise utilisation at all times.

Results

• 7% Reduction of material handling fleet (500k/yr saved)
• 80% reduction of forklift damage costs
• $2M Per year labour efficiency again
• Reduced gaps in activity and productivity
• 100% compliance for vehicle safety checklists
• Hour-by-hour, day-by-day monitoring of vehicle utilisation for immediate leadership action
• Large-scale data source for ongoing improvement strategies

The client reports that, “Very quickly, we were able to reduce forklift damage costs over 80% and get our pre-shift checks into 100% compliance.”

Conclusion

Powerfleet's solutions provided new data sources and improvement plans for this global manufacturer. Across numerous facilities and hundreds of vehicles, these systems significantly improved functionality and streamlined processes. Operations and personnel were improved through Powerfleet’s sophisticated, innovative digital tools.