Lift Truck Telematics & Distribution Operations

Lift Truck Telematics & Distribution Operations

Powerfleet® removed risk factors and applied enforceable safety
measures for a large food manufacturing company. Each location
received technologically advanced and easily implemented processes
for worker safety and vehicle tracking. Powerfleet®’s advanced telematics digitize tracking, enabling management at any location
to monitor vehicle use and employee habits. This eliminated guesswork, provided accountability and created a new system of checks and
balances for measurable results. The company saw results in terms of a 70% decrease in accidents, an 80% decrease in damages and several hundred thousand dollars in cost savings.

Situation

Powerfleet®’s advanced telematics digitize tracking, enabling management at any location to monitor vehicle use and employee habits. This eliminated guesswork, provided accountability and created a new system of checks and balances for measurable results.

The company saw results in terms of a 70% decrease in accidents, an 80% decrease in damages and several hundred thousand dollars in cost savings.

Task

Improvements were required in the following areas:

  1. Control over 3PL operations, specifically equipment use, personnel training, and accountability.
  2. Reduction of industrial truck accidents and vehicle damage, which was costing the company nearly half a million dollars each year.

The company has a fleet of over 150 industrial trucks, which include motorized walkie-rider pallet jacks, reach trucks and sit-down counterbalance forklifts. They required immediate help with monitoring personnel and reducing safety threats.

Action

Powerfleet® is an expert in streamlining safety operations. The intelligent designs and systems improvement transformed this company’s operations, drastically reducing risk and improving safety. The company needed a wireless telematics system designed for industrial trucks. Powerfleet® put into place:

  • Access control system: this ensures that only trained operators are using certain types of equipment and vehicles in need of repair are locked.
  • Electronic safety lists that comply with OSHA regulations and can identify mechanical issues before they become critical or dangerous.
  • Collision detection and accident management, which logs the identity of the driver when impact occurs.

Based on pricing, reliability and overall value, this company selected Powerfleet® as the best option on the market to implement these systems.

Powerfleet®’s services provide OEM-independent solutions over a long period of time. They implemented the above systems, many of which are patented and unique to Powerfleet® as a company.

Powerfleet’s® implementation of software and hardware happened over the course of just a few weeks.

Powerfleet Took These Steps

  • Vehicle-mounted devices that include on-screen Wizard
  • Integrated with existing systems
  • Validated system’s interface with every brand of truck
  • Ensured accurate and consistent data flow
  • Installed badge-reading technology for existing employee ID cards
  • Vehicle access control
  • Installing a patented electronic safety checklist system

Results

The client reports that Powerfleet® achieved the following results:

  • Real-time data for deep fleet utilization
  • Authentic monitoring of how operators are using equipment
  • Improved processes and efficiency
  • Increased productivity of material handling operations

Additional outcomes eliminated badge-sharing among employees, created a “driver break” function to prevent unauthorized vehicle use and actioned an alert system for any maintenance issues or safety violations. The combined efforts had the additional results of:

  • Eliminating cost, time and trouble of paper-based records and communication
  • Early identification of equipment repair needs
  • Reduction in unsafe operation procedures and expensive repairs
  • A higher rate of vehicle mobilization and safe use (due to timely repairs)

Conclusion

Powerfleet®’s patented, industrial management technology transforms drivers’ situational awareness and reduces the number of accidents. It streamlines real-time communication and eliminates false alarms. Managers can respond quickly to accidents or safety events and create proactive measures to avoid costly issues. With integrated systems, meaningful data can be collected that informs best practice and better processes for the companies who use Powerfleet®’s software and hardware.

Learn how Powerfleet® can help your business.

Powerfleet transforms the way organizations manage mobile business assets — like forklifts, cargo trailers, and connected cars. Our technologies control, track, analyze, and optimize hundreds of thousands of these assets all over the world. We help organizations be safer, improve efficiency, and cut costs.

Let us help transform your business.

Global Manufacturer Telematics & Analytics

Global Manufacturer Telematics & Analytics

Operational Suport, Telematics, and Software Systems

Powerfleet® provided operational support, telematics and software
systems that transformed safety and improved revenue for a global
manufacturer. Powerfleet®’s forklift fleet management and analytics provide real-time data. This protects workers by remote vehicle
monitoring, maintenance alerts and reduction of costs associated with lift truck accidents. Additionally, telematics 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 at five manufacturing plants with over 800 vehicles of varying types. They achieved millions of dollars in labor costs, 80% forklift accident reduction and 100% personnel safety compliance.

Situation

A global manufacturer needed solutions for heavy manufacturing processes. These occurred in five separate locations and used about 800 vehicles,  including lift trucks, tow tractors and man lifts. 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 of personnel safety due
    to negligence.
  3. Better data for access control, employee checklists and vehicle
    status reporting.

The company had (or has) 800 material handling equipment (MHE) vehicles in five locations. Each goal would have to be achieved in different environments, with different leadership and employees.

Action

Powerfleet® sets the standard in the industry for safety enforcement and efficiency for industrial vehicles and access control systems. Powerfleet® put into place:

  • Access control system: this system created digital records for every driver, using their existing employee ID cards. Tied to training databases, access is only granted to employees who are both certified and authorized to operate a vehicle.
  • Electronic safety lists that prioritize the OSHA top-10 industrial safety
    concerns and provide a bank of useful data from which managers can adjust processes and quickly address any issues.
  • Collision detection and accident management, Powerfleet®’s patented system flags impact severity and prompts management responses. This
    is an efficient system which logs accidents, eliminates down time and reduces the number of vehicles that are 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.

Powerfleet Took These Steps

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

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

Additionally, leadership at the company began to use Powerfleet® IQ™ Analytics to assess their systems. This source of information provided both a baseline and immediately identifiable areas for improvement which provided immediate action items for improvement in low-performing sites. They were able to reduce waste and improve operations for maximum utilization at all times.

Results

The client reports that Powerfleet® achieved the following results:

  • Reduced gaps in activity and productivity
  • 100% compliance for vehicle safety checklists
  • Hour-by-hour, day-by-day monitoring of vehicle utilization 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 telematics and Powerfleet® IQ™ Analytics provided a novel source of data and improvement plans for this global manufacturer. Across numerous facilities and on hundreds of different vehicles, all of these
systems vastly improved function and streamlined processes. Operations
and personnel were improved through Powerfleet®’s sophisticated,
innovative, digital tools.

Learn how Powerfleet® can help your business.

Powerfleet transforms the way organizations manage mobile business assets — like forklifts, cargo trailers, and connected cars. Our technologies control, track, analyze, and optimize hundreds of thousands of these assets all over the world. We help organizations be safer, improve efficiency, and cut costs.

Let us help transform your business.

Forklift Telematics & Analytics

Forklift Telematics & Analytics
Reduced Risk & Increased Revenue

Powerfleet® reduced risk and increased revenue for the customer in this case study. Innovators at Powerfleet® undertook this project for a client in automotive manufacturing by providing fleet management and analytics for five manufacturing plants. These plants had an industrial truck fleet of over 800 vehicles, including lift trucks, tow tractors and man-lifts. The work performed saved the company over $2 million a year and continues to pay off in terms of efficiency and effectiveness.

Situation

A leader in global automaking found themselves in need of improved safety measures and material handling operations. The company adheres to the highest safety standards but their ongoing self-monitoring processes indicated a need for improvement. The need extended to personnel training, systems implementation, systems management, authorization processes and equipment use monitoring.

Task

This automaker needed safety and operational improvement for two reasons:

  1. The protection of its workforce
  2. To reduce the cost of lift truck accidents

The company is known for safety technologies. The workforce in new safety systems included people working on forklifts and other MHE. Powerfleet’s objective was to improve control over industrial truck safety policies. The work and systems implemented by Powerfleet® addressed the client’s acute and long-term needs.

Action

Powerfleet® excels in logistics, industrial telematics and vehicles. Two of Powerfleet’s tools were used in this case:

  1. Powerfleet telematics: a logistics system that manages transportation assets according to regulatory compliance and client-specific metrics.
  2. PowerfleetIQ® Analytics: proprietary software which provides advanced data search, sorting an analysis, seamlessly integrated and accessible from any device.

These tools provided a dual-action solution to the automaking company’s safety needs.

Powerfleet Took These Steps

  • Data analysis that measured forklift productivity and identified underperforming sites and peak activity.
  • Vehicle operator relocation and fleet reduction recommendations.
  • Implemented an access control system for operators that connected to the plant’s database. This ensured that only authorized, trained employees could operate vehicles.
  • Deeper access control was created that grouped operators by department and shift, giving management the ability to monitor workers.
  • Provided an electronic safety checklist system for industrial truck operators.
  • Utilized the Powerfleet patented impact management system that streamlines notification and alerts to managers.

Results

Powerfleet saved this client millions of dollars and put a system in place that will benefit their business in numerous ways. Results of this work included:

forklift-telematics-analytics

Conclusion

Powerfleet® is uniquely equipped to assist companies in numerous facets of this industry. Our cutting-edge technology and applied practices can improve systems and optimize efficiency. In this case, our work ensured the safety of employees and reduced costs.

Learn how Powerfleet® can help your business.

Powerfleet transforms the way organizations manage mobile business assets — like forklifts, cargo trailers, and connected cars. Our technologies control, track, analyze, and optimize hundreds of thousands of these assets all over the world. We help organizations be safer, improve efficiency, and cut costs.

Let us help transform your business.

Trailer Management Systems Boost Revenue, Save >$1 Million for 3PL

Trailer Management Systems Boost Revenue, Save $1 Million for 3PL

ReedTMS Logistics

Background

ReedTMS Logistics (www.reedtms.com) is a family-owned, third-party logistics provider (3PL). The company delivers a broad range of 24/7 services, including:

  • Brokerage
  • Transportation
  • Freight management
  • Dedicated services
  • Asset-based services

ReedTMS has quadrupled in size since its founding over 20 years ago. It now operates a private fleet of 85 trucks and 400 dry vans, tankers, and other trailers. With these assets, ReedTMS handles close to 100,000 shipments a year, serving hundreds of customers across a variety of industries

“Powerfleet’s solutions gave us the tools we needed to run the most efficient—and profitable—trailer fleet.”

Chad Walz
VP Operations,
ReedTMS Logistics

The Challenge

Like all carriers, ReedTMS wanted to move more loads to increase revenue and profits. At the same time, the company wanted to control expenses and cut unnecessary costs.

A fixed asset base of tractors, trailers, and infrastructure means fixed costs. If you can ship more freight with those assets, while managing costs, naturally you’ll earn more revenue-dollars per cost-dollar. And that, of course, equals higher profits.

ReedTMS decided that the smartest way to ship more loads, cut costs, and boost profits would be to increase asset utilization. Specifically, the company wanted to:

  • Optimize trailer pool size
  • Maximize driver efficiency
  • Minimize empty trailers

With 80% of its business from dedicated or semi-private fleets, ReedTMS uses trailer pools to deliver the highest level of customer service. If it could reduce the size of those pools, without affecting service, it could reduce costs. And if ReedTMS could help its customers process trailers more quickly, it could maximize the capacity of those pools. Either way, the improved asset utilization would increase profit margins.

Trailer pools are also key to make the most efficient use of drivers’ time. ReedTMS wanted to operate its fleet 20-24 hours a day by effectively managing short hauls, with a high trailer-to-truck ratio. Short hauls could keep the assets moving, without exceeding any driver’s daily ELD limit of 14 hours. As an added bonus, this approach would make drivers happier, by letting them get home at the end of each day.

One downside of trailer pools is that empty trailers can dwell at a site for too long. This impacts both costs and revenue. For example, one ReedTMS customer received four loads in for every one load out, leaving many empty trailers to manage. As a result, drivers sometimes weren’t sure which trailers were empty, or where they were located. This could cause drivers to waste time searching for empties—and hit their 14-hour ELD limit. Without a backhaul, those drivers had to stay overnight and pay for a hotel. On top of that, the idle, empty trailers lost an opportunity to generate more revenue.

The Solution

ReedTMS started monitoring trailer locations with a basic Track and Trace solution from PowerFleet. This was perfect for locating missing trailers, and it quickly generated a positive return on investment (ROI). (See details under “The Results,” below.)

But to achieve the highest level of efficiency—to proactively manage trailer pools, drivers, and empties in real time—ReedTMS decided it needed an even more capable solution. So it turned to PowerFleet’s Dry Van Trailer Tracking system.

This system lets you know exactly where and when a trailer starts and stops, how long it dwells, and whether it’s loaded or empty. What ReedTMS liked most about the system was its:

  • Easy installation
  • Extended battery life
  • Real-time location tracking
  • GPS-based mileage reporting
  • Sensors for full-trailer cargo detection, with time stamps for start and end of loading

Implementation

To install its new trailer tracking technology, ReedTMS needed to make the most efficient use of time, so it could keep fleet utilization high. To achieve this, the company used a two-prong approach.

First, ReedTMS ordered any new trailers it needed with the Dry Van Tracking System pre-installed. PowerFleet worked directly with the trailer OEMs to make this process smooth and reliable.

Second, for its existing trailers, ReedTMS installed Dry Van Tracking devices during normal planned maintenance (PMs). Fortunately, at most, the devices take only 60-90 minutes to install. So mounting them didn’t overload resources or delay the trailers from getting back on the road.

As an added level of support, PowerFleet integrated its web-based Powerfleet IQ™ asset tracking software with the McLeod software that ReedTMS already used for dispatching. As a result, ReedTMS could see—in real time—trailer distance from landmarks, dwell times of idle trailers, “dropped balls” in the dispatch process, and much more. Ultimately, these combined systems will proactively match dispatch orders with live trailer locations, which will prevent dispatch errors from occurring in the first place.

In addition, PowerFleet introduced ReedTMS to its Powerfleet IQ™ Analytics platform. This “big data” application crunches numbers from multiple sources to uncover deeper insights into operations. For example, ReedTMS plans to use FleetView IQ to integrate its trailer tracking and dispatch systems with ELOG, GPS, ELD and engine data from its tractor management system.

“From finding lost trailers and right-sizing our trailer pools to reducing new trailer buys, our tracking system has added over $1 million to our bottom line.”

Chad Walz
VP Operations,
ReedTMS Logistics

Results

Initially, the value of trailer tracking for ReedTMS was simply in finding trailers. For example, one customer would share trailers with different carriers, which sometimes resulted in a misplaced unit. Tracking the location of these “lost” trailers enabled ReedTMS to recover them easily. That alone saved the company hundreds of thousands of dollars in capital costs. Not to mention the cost of man-hours (and aggravation) it would have spent filing insurance claims.

But by switching to the Dry Van Trailer Tracking system—with its advanced cargo and load sensing, as well as “live” trailer location tracking—ReedTMS has been able to do (and save) much more:

  • Find empty trailers in real time. This is especially critical at the end of the week, when customers need empties to load.
  • Locate specific assets near customer locations without drivers searching for them. This reduces both the hard and soft costs of driver and trailer down-time.
  • Improve fleet utilization. ReedTMS has achieved a trailer-to-truck ratio as high as 3.75 to 1, with minimal idle trailers.
  • Direct decisions on new trailer buys/rentals. By right-sizing its trailer pools, ReedTMS has avoided over $1 million in capital costs. And generated more revenue per trailer.

The Powerfleet IQ software report that ReedTMS uses the most is an “Idle Trailer Summary.” It shows how long a trailer has been sitting still. Focusing on this data has helped ReedTMS reduce dwell time significantly. Management believes it can cut the average down to as little as 5 days.

ReedTMS uses this data to proactively manage customers and increase asset utilization. For example, if a loaded trailer remains at a customer site too long, ReedTMS will ask the customer to prioritize shipment, or charge the customer a storage fee. On the other hand, if a trailer in a customer’s dedicated pool sits empty on a regular basis, ReedTMS will pull the asset to use elsewhere and charge the customer less for the smaller pool.

Conclusion

By using advanced asset tracking technology, ReedTMS has been able to proactively manage its trailer pools, drivers, and empties—and improve dispatch efficiency. This visibility and control has helped the company increase asset utilization, reduce costs, and achieve its goals for revenue-per-asset.

ReedTMS now spends much less time waiting to pick up loaded trailers, unload trailers after delivery, and put empty trailers back into service.

“The key to our business is asset allocation and utilization, and I.D. Systems’ Logistics Visibility Solutions gave us the tools we needed to run the most efficient—and profitable—trailer fleet,” said Chad Walz, Vice President of Operations for ReedTMS Logistics. “From finding lost trailers and right-sizing our trailer pools to reducing new trailer buys, our tracking system has added over $1 million to our bottom line.”

Powerfleet transforms the way organizations manage mobile business assets — like forklifts, cargo trailers, and connected cars. Our technologies control, track, analyze, and optimize hundreds of thousands of these assets all over the world. We help organizations be safer, improve efficiency, and cut costs.

Let us help transform your business.

Forklift Analytics Cut Damage Costs 85%

New Lift Truck Metrics Help Save
Food & Beverage Maker Over $2 Million

Challenge: In a Hyper-competitive Market, Do More with What You Have to Cut Costs

Five years ago, a leading multinational food & beverage company deployed Powerfleet’s® forklift telematics system to improve material handling safety. The project was a big success. Based on its initial return on investment (ROI), the Company rolled out Powerfleet on more than 2,500 pieces of material handling equipment across almost 100 of its food and beverage manufacturing and distribution sites in North America.

But with more than $60 million invested in its material handling fleet—and a labor cost of over $200 million to run that fleet—the Customer wanted to find out if Powerfleet could save it even more money.

Center of Excellence Looks to Expand Use of Powerfleet

This Company has a long history of using cutting-edge supply chain technology. For example, it is a leader in blockchain technology for sharing data securely across the food supply chain to help ensure food safety. The Company’s Center of Excellence (CoE) focuses on continuous improvement in manufacturing and distribution, with data as its life blood.

To find new ways to reduce material handling costs, one of the key data sets the CoE wanted to understand better was the relationship between lift truck safety and productivity.

With Powerfleet forklift telematics already in place across the Company’s entire fleet of lift trucks, the CoE didn’t have to look far to find the data-driven solution it needed.

Solution: Powerfleet IQ™ Forklift Analytics

To gain deeper insight into the cost of lift truck safety vs. operator efficiency vs. material handling velocity, the Company licensed Powerfleet IQ Analytics, a Powerfleet software option, to link data from multiple sources.

Specifically, the Company wanted to use Powerfleet IQ to blend these data ingredients:

  • Number of damage-causing impacts recorded by forklift operators
  • Time forklift operators spent actively working
  • Number of pallets moved by lift truck operators

Key Considerations

Before launching a new technology for its material handling workforce, the Company knew from experience it needed to plan carefully and be proactive about the way it would use the data.

One of the pitfalls of data-driven technology, like Powerfleet IQ Analytics, is that the data can be overwhelming. Another challenge is translating the data into action. All too often, a flood of data is received passively, without a clear vision of what to look for or how to react.

For any new system to succeed, the people who will get the data need to know ahead of time what they will be looking for—and exactly what they are supposed to do with it.

A Carrot and Stick Plan

The Company knew that for Powerfleet IQ to be most effective, key employees—lift truck operators, line supervisors, facility managers, and corporate management—needed to care about the outcome. The Company had to make more than a financial investment; it had to engage and motivate these stakeholders.

The key to making workers care is accountability. So the Company devised a “carrot-and-stick” plan with both incentives for “good” behaviors and consequences for “bad” behaviors. Using Powerfleet IQ Analytics data, the Company:

  • Developed a consistent set of metrics for material handling productivity and safety, regardless of the type and size of a facility, or the makeup of a site’s lift truck fleet.
  • Established new benchmarks for pallet moves vs. lift truck motion time and impact events.
  • Set up key performance indicator (KPI) scorecards for drivers, supervisors, and warehouse managers.
  • Awarded cash bonuses and other incentives for meeting target KPIs.
  • Retrained or reassigned forklift operators who failed to meet the benchmarks for safe productivity.

Results: Deep Data Insights Cut Forklift Damage 85% while Meeting/Exceeding Pallet-Move Goals

To better measure what sites and people needed a better balance of material handling productivity and safety, Powerfleet worked closely with the Company to integrate its Kronos® time-card system and SAP® warehouse management system (WMS) with Powerfleet IQ Forklift Analytics. This created a whole new set of integrated data points, such as:

  • Lift truck operator paid-time vs. seat-time, deadhead-time, and time-in-motion-with-load
  • Lift truck impacts vs. number of pallets moved

An excerpt of the latter type of chart is shown below, with the data aggregated by site. In this example, the “Demarest” site moves almost as many pallets as “Cresskill,” but with about half as many moderate and medium impact events. The user can click on any site to drill down into individual driver performance at that site, to determine which operators were at the root of the data.

Powerfleet and the Customer also built KPI scorecards, so all the critical metrics could be digested in one quick bite. The following examples focus on, respectively, forklift fleet safety and productivity, by site. In the KPI scorecard excerpted below, the screen shows the 7-day safety rankings and 30-day trends of each site, based on their forklift fleets’ rate of high and severe impacts. Green dots indicate compliance with corporate standards; yellow dots suggest improvement is needed. (Red dots would indicate a site’s performance is unacceptable.)

The next KPI scorecard excerpt ranks sites by forklift fleet efficiency, based on the amount of time vehicles spend in motion compared to the time vehicle operators are logged into the equipment. The “Demarest” site makes the most efficient use of its equipment—it has the highest ratio of motion (time vehicles are moving) to login (time drivers are logged in)—even though the site is average in its total hours of equipment usage. Conversely, although “Montvale” seems to be among the busiest sites, in terms of total hours of equipment usage, it is actually the lowest-performing in its ratio of vehicle motion time to driver login time.

“Powerfleet IQ Analytics drove much safer lift truck operations without a loss of material velocity: 85% less forklift damage and 100% of target pallet moves … for over $2 million in cost savings across the enterprise.”

Process for Validation and Action

The first key role of Powerfleet IQ was to validate data accuracy. One KPI scorecard monitored the health of system components—particularly to confirm that the Powerfleet vehicle-mounted hardware was collecting data normally and attributing it to identified operators. With validated data flowing smoothly, the Company went through a period of analysis over several months, without acting on the data. This enabled the Company to set expected benchmarks without rushing to judgment about individual operator performance. Importantly, the established benchmarks were ratios (not absolute numbers) to normalize performance across operators, vehicle types, and sites with different operating patterns.

The most critical benchmark ratios were:

  • Pallets moved to severe forklift impacts (which have a high correlation to damage) and to medium forklift impacts (an indicator of excess wear and tear over time)
  • Vehicle motion time to operator login time to Kronos® shift time

Also significantly, Powerfleet IQ enabled different standards to be set for different vehicle types, and accounted for drivers who operated different types of vehicles in same shift or day.

Based on these benchmark ratios, the Company set up multiple KPI scorecards for different stakeholders: individual drivers (with daily, weekly, and monthly metrics); supervisors (focused on all drivers each shift); warehouse managers (with a view of the entire facility); and corporate management (with stack-ranking of all sites in a single view).

This data hierarchy enabled a rapid, logical flow of information and decisions. Corporate management identified high- and low-performing sites. Facility managers saw where they ranked compared to other sites, and where they stood in relation to the target benchmarks. Line supervisors drilled down to understand which forklift operators were high achievers—and which needed refresher training. And forklift operators could see in black-and-white where they stood.

In the end, the food & beverage Company was able to drive much safer lift truck operations while maintaining high material velocity through its distribution system. The result was an 85% reduction in forklift damage costs with 100% achievement of target pallet moves.

Why Did Powerfleet IQ Analytics work so well?

“We worked with Powerfleet to integrate data from several systems and set up new benchmarks for safety and productivity. We validated the data, then analyzed it to identify specific opportunities to improve. By focusing on the sites and people that needed the most improvement, we were able to reduce forklift damage costs 85% while maintaining—or exceeding—our goals for pallet moves.”

— National Warehouse Manager

That damage reduction equated to well over $2 million in cost savings across the Company’s enterprise.

Conclusion: New Ways of Combining and Analyzing Lift Truck Data Can Radically Improve Material Handling Operations

Using Powerfleet IQ forklift analytics, this food and beverage Company was able to change the way it measured and balanced productivity (pallets moved) with safety (forklift collisions) and efficiency (active time on equipment vs. paid time). This data enabled a new approach to material handling discipline, with high-performers rewarded with financial and other incentives, and low-performers trained to improve. The bottom line was a stronger safety culture, with a new way to measure and manage productivity.

  • Compliance with key safety metrics increased to essentially 100%
  • Accidents and damage decreased more than 85%, while pallet moves remained at target levels
  • Company-wide, Powerfleet IQ Forklift Analytics helped add more than $2 million in cost savings to the bottom line

Powerfleet transforms the way organizations manage mobile business assets — like forklifts, cargo trailers, and connected cars. Our technologies control, track, analyze, and optimize hundreds of thousands of these assets all over the world. We help organizations be safer, improve efficiency, and cut costs.

Let us help transform your business.

Powerfleet® Key to Forward Air Growth Strategy for Fleet Tracking and Management

Powerfleet® Key to Forward Air Growth Strategy for Fleet Tracking and Management

“Since adding Powerfleet®, our business grew, our fleet grew, however, our need for trailers did not grow proportionately, due to the increased utilization that tracking helped provide.”

Tim Parker
Vice President of Service Operations
Forward Air

Increased Utilization

Forward Air Corporation is a leading provider of time- definite surface transportation and related logistics services to the North American air freight and expedited LTL market. In 2007, Forward Air began deploying the Powerfleet trailer tracking devices across its LTL trailer fleet, supporting deliveries through its central hub in Columbus, Ohio and 11 regional hubs to 85 cities across North America. Since implementation of the system began, Forward Air has grown its core business and added three new business groups.

Offering New Services

“Forward Air added new services such as intermodal drayage, pool distribution, expedited truck load operations, and a door-to-door offering- Forward Air Complete,” explains Tim Parker, Forward Air’s Vice President of Service Operations. “These new services required equipment to be placed at customer locations and to occasionally be pulled by non-FAF power units. The visibility and control of our equipment was significantly reduced. Adding Powerfleet Track-and-Trace improved visibility at every location.”

Improved Operations

After initially using Powerfleet to react to questions about how their trailers were being used, the company’s application of the system evolved with more active use, removing the need for manual yard checks. As a result, identification of misused assets became more efficient, and the manpower dedicated to daily monitoring of each site’s inventory was reduced.

Operations managers at each of Forward Air’s 85 local stations use Powerfleet to perform yard checks at their locations, as well as at customer yards that belong to their pool. The Powerfleet FleetView platform website dormancy reporting capabilities are then used to help identify excess trailers that can be eliminated from their pool.

In 2010, Forward Air began replacing their existing Powerfleet tracking devices with Powerfleet’s new Track-and-Trace product. Benefits of the low-cost device include the ability to ping for trailer location on demand, which is critical to locating stolen assets or other moving targets. With an up-to-date trailer position, drivers on trailer search missions can be routed directly for pick up, saving valuable hours of service and fuel costs dedicated to hunting for misplaced units. Maintenance budgets have also benefited from the addition of the new devices due to ease of installation and battery replacement, plus the assistance it provides maintenance managers in scheduling service.

After initially using Powerfleet to react to questions about how their trailers were being used, the company’s application of the system evolved with more active use, removing the need for manual yard checks. As a result, identification of misused assets became more efficient, and the manpower dedicated to daily monitoring of each site’s inventory was reduced.

Operations managers at each of Forward Air’s 85 local stations use Powerfleet to perform yard checks at their locations, as well as at customer yards that belong to their pool. The Powerfleet FleetView platform website dormancy reporting capabilities are then used to help identify excess trailers that can be eliminated from their pool.

In 2010, Forward Air began replacing their existing Powerfleet tracking devices with Powerfleet’s new Track-and-Trace product. Benefits of the low-cost device include the ability to ping for trailer location on demand, which is critical to locating stolen assets or other moving targets. With an up-to-date trailer position, drivers on trailer search missions can be routed directly for pick up, saving valuable hours of service and fuel costs dedicated to hunting for misplaced units. Maintenance budgets have also benefited from the addition of the new devices due to ease of installation and battery replacement, plus the assistance it provides maintenance managers in scheduling service.

Improved Customer Service

The benefits of Track-and-Trace have extended to Forward Air’s customers as well. Forward Air customers can access the VIP website to monitor the location and security of their loads.

“The quick set up and intuitive format of the VIP website has allowed us to extend the value of the product directly to our customers,” added Parker. “Our customers can log in to the website and view their specific information to help them better manage their equipment and utilization levels. We also rarely have to burden our customers with manual yard checks. Instead, the customers are empowered to quickly ascertain their equipment and utilization levels.”

Powerfleet has helped Forward Air improve their trailer fleet utilization by 15%, while also improving bottom line performance by an estimated $500,000 per year.

Powerfleet transforms the way organizations manage mobile business assets — like forklifts, cargo trailers, and connected cars. Our technologies control, track, analyze, and optimize hundreds of thousands of these assets all over the world. We help organizations be safer, improve efficiency, and cut costs.

Let us help transform your business.

Powerfleet® Provides Critical Security Benefit

Powerfleet® Provides
Critical Security Benefit

“Without Powerfleet for Logistics solutions, the odds of recovering stolen goods are low. Word is likely to be out on the street that Knight is not a desired target given our tracking capabilities.”

Richard Martin
Corporate Director of Security,
Knight Transportation, Inc.

Theft Recovery No. 1

In Long Beach, CA, a Knight Transportation driver reported that his truck and trailer were missing. The security department immediately enabled Emergency Track on its Powerfleet for Logistics system to begin the trailer location process. It was discovered that the trailer traveled throughout the previous night ending its journey in Rialto, CA at 8:51 a.m. The authorities were notified of the stolen trailer and were told exactly where it was parked, based on the last location delivered by the Powerfleet system. Surveillancewas immediately established across from a large warehouse facility.

Mission Success– The missing trailer came out of the warehouse hooked to a different tractor. The rig was followed by police and the driver was arrested. The authorities recovered all 111 televisions valued at over $100,000, as well as the tractor. Interestingly, a container was also retrieved containing fabric worth over $250,000 that wasn’t yet reported stolen. Several more arrests were made at the scene.

Theft Recovery No. 2

A Knight Transportation tractor and trailer were reported missing during a particularly busy night in the middle of the peak holiday season. Using the VeriWise system’s reporting features, authorities were able to pinpoint the last known location of the trailer in Compton, CA. Upon arrival at the site, the tractor and trailer, minus the cargo, were recovered. Knight security personnel then back-tracked through the location history of the trailer provided by the system’s best-in-class user interface. It was discovered that the trailer had been parked for several hours the night before in Long Beach, CA at the site of a warehouse and storage facility.

Victorious Recovery – A search warrant was obtained for the warehouse where the authorities found the stolen load of electronics equipment valued at over $335,000. Two additional stolen loads were recovered as well. Over 200 televisions were recovered that were shipped from China and reported stolen. In addition, a load of cosmetics was also recovered and returned to its owners.

Estimated Recovered Value: Over $1 Million. Powerfleet not only improves the efficiency of managing Knight Transportation’s trailer fleet by increasing overall trailer utilization, it also provides a critical security benefit in greatly increasing the chances of recovering stolen cargo.

Powerfleet transforms the way organizations manage mobile business assets — like forklifts, cargo trailers, and connected cars. Our technologies control, track, analyze, and optimize hundreds of thousands of these assets all over the world. We help organizations be safer, improve efficiency, and cut costs.

Let us help transform your business.

[help]

Achieving Your Data Utopia

With Unity, Powerfleet transforms supply chain management by centralizing data streams, applying AI innovation, and simplifying integration.

[help]

Car Rental

[help]

Advance to a New Era of Safety with Vision AI

Safety is the pulse of the transport industry, a mandate beyond mere goals. We stand as your ally in this mission. Meet Vision AI – your trusted co-pilot, for a safe trip every time.

[help]

Revolutionize Compliance with Driver-Focused ELD

Upgrade to our Next Gen ELD – effortless compliance, driver-focused, and built for flexibility with an open platform that grows with your fleet.

[help]

MiX Vision AI S

MiX Vision AI S merges vehicle tracking and advanced single-camera video for easy installation and quick performance. It monitors vehicle location, driver behavior, and driving quality to inform decisions and boost fleet safety and efficiency.

[help]

Keyless Gateway

Plug & Play Wireless Control, Tracking, and Monitoring for Rental and Leased Fleets

[help]

Explainer Video: Solutions for In-Warehouse and Manufacturing Facilities

Powerfleet’s purpose-built solutions for warehouses and manufacturing facilities are revolutionizing fleet operations for organizations of all sizes and helping bring safety to the forefront.

[help]

Powerfleet Brand Video

[help]

Unity APIs

Streamline Data Integrations and Empower Informed Decision-Making

[help]

Pedestrian Proximity Detection

AI-Enabled Vision System for Pedestrian and Vehicle Safety Warning