Manufacturing and warehousing have the second-largest rate of preventable fatal work injuries of any sector—ahead of mining and construction.. In fact, approximately 11% of forklifts in the U.S. will be involved in an accident each year. In 2022 forklifts were responsible for 78 work-related deaths and 7,290 non-fatal injuries that affected days away from work. A serious injury usually involves worker hospitalization, days away from work and in some cases permanent disability, while a single forklift accident can cost $180,000 or more. So, if your facility has ten or more forklifts, there’s a good chance that you will experience at least one accident per year.

Fortunately, new technologies are improving workplace safety. For example, cameras provide forklift operators with increased visibility, LEDs alert pedestrians of a forklift’s presence in noisy work environments, and sensors aggregate safety data and enable managers to address problems before they result in injuries or fatalities.

Let’s take a look at breakthroughs in pedestrian warning systems and why you may want to consider them for your forklift fleets.

Forklifts are responsible for more than 96,000 non-fatal injuries each year, but fortunately, safety technologies are quickly improving—including new pedestrian warning systems. Click To Tweet

Forklift Safety Challenges

Material handling equipment like forklifts frequently run products or materials throughout environments such as factories, plants and warehouses where pedestrians are present. The combination of fast-moving vehicles, blind corners, and a noisy environment create inherent risks that lead to fatal and non-fatal accidents.

Some common challenges include:

• Operators cannot simultaneously look at what they’re doing and be completely aware of their surroundings.
  
• Vertical stacking is necessary to maximize efficiency but creates the risk of dangerous falling objects.
  
• Loud work environments and hearing protection reduce the effectiveness of audible warnings like horns.

While some of these problems remain unavoidable, new technologies eliminate others, opening the door to safer work environments. Facility and equipment managers may want to consider adopting these technologies to prevent costly safety incidents. As a bonus, many of these technologies simultaneously provide actionable business intelligence.

AI-based Camera Solutions

Artificial intelligence, or AI, has made tremendous strides over the past several years. In particular, AI has become quite adept at recognizing objects, enabling machines to distinguish between pedestrians, other vehicles, signs and objects. These same technologies could also solve key forklift safety challenges.

While forklift cameras provide some level of visibility, operators cannot be watching camera feeds at all times—they also need to collect loads and transport them to their destination. AI-powered cameras provide an extra set of eyes by automatically recognizing the human form in any camera and triggering real-time alerts.

These systems improve upon traditional pedestrian monitors, which require tags that must be worn at all times by anyone walking around in a warehouse. AI-powered cameras don’t require any special equipment or procedural changes. You can mount multiple cameras to provide extra safeguards when it comes to pedestrian safety hazards.

 

The Pedestrian & Vehicle Warning System automatically detects pedestrians and ensures safety regardless of the PPE they’re wearing. Source: Powerfleet

Powerfleet’s Pedestrian and Vehicle Warning System doesn’t require the use of any tags or high-visibility vests to detect pedestrians, ensuring safety regardless of PPE standards. When combined with industrial telematics data, it can provide additional insights for identifying areas for improvement and driver coaching to help you promote a culture of safety at your facility.

Pedestrian & Vehicle Warning Systems

Powerfleet’s Pedestrian and Vehicle Warning System uses AI and up to three cameras to help prevent accidents and protect pedestrians, goods, and facilities. With two fully-configurable, 120-degree, field-of-view zones for each camera, you can provide operators with visual and audio advanced warning and critical action based on a hazard’s proximity.

Unlike many competing solutions, the Pedestrian and Vehicle Warning System doesn’t require pedestrians to wear special apparel or wearable tags and the system activates based on the direction of travel to avoid false positives. When capturing images of a dangerous event, the system also blurs out faces to ensure privacy while capturing data to help managers assess the situation.

 

Additional Pedestrian Safety Technologies

Non-camera based safety accessories such as Powerfleet’s Forewarner systems are also helpful in alerting pedestrians of nearby forklifts. Rather than relying on horns in noisy environments, Forewarner systems project a bright spot  on the floor’s surface. With about 15 feet of warning time, pedestrians have a visible warning to get out of the way.

Other forewarning systems project solid blue or red LED lines below overhead crane hook locations. That way, pedestrians are immediately aware of any overhead risks that they may not be paying attention to when walking past. And like the other forewarners, these projections don’t rely on hearing in a noisy environment.

Powerfleet provides a range of visual forewarning systems, including its Forewarner Sideliner LED, and Forewarner MAXI for overhead objects. As with the Pedestrian and Vehicle Warning System, these technologies work with other telematics to improve overall safety and performance, creating a robust safety culture.

Cameras & Telematics

Many forklift safety hazards arise from risky driving habits. For example, overconfident drivers may speed back and forth when moving materials. Telematics provide an easy way to monitor these driving habits and address any problems before they result in injuries or fatalities. And when paired with cameras, you can use incident recordings for evidence or training footage.

Powerfleet’s advanced telematics platform provides wireless, automated control, and monitoring of industrial vehicles. Managers can receive alerts in real-time through a cloud-based portal for analytics, coaching, and other purposes.

The combination of AI-powered cameras and telematics can help make your drivers safer and more productive with fewer accidents. In addition, you can ensure compliance with OSHA regulations and other workplace guidelines while minimizing liability.

The Bottom Line

Pedestrian safety is essential in manufacturing, warehouse, and other environments where material handling equipment is in use. While the combination of fast-moving vehicles, blind corners, and a noisy environment can create many hazards, new technologies proactively alert both operators and pedestrians when risky situations arise. The result is fewer safety incidents and a more streamlined work environment.

If you’re interested in transforming your fleet safety, contact us today, to schedule a free consultation.

AT&T phased out its 3G network on February 22, 2022, leaving unprepared fleets at risk for lack of ELD compliance and zero visibility. In addition, fleets lost real-time data from sensors, trackers, and other technologies installed across their fleet. The lack of historical data could skew analyses even after an emergency migration to 4G LTE.

T-Mobile sunset Sprint’s 3G CDMA on March 31, 2022, and plans to shut down its 3G UMTS network on July 1, 2022. And Verizon will shut down its 3G CDMA network on December 31, 2022. In the meantime, many carriers are repurposing spectrum in certain geographic areas, causing slowdowns and impacting connectivity well before these deadlines.

Fleets shouldn’t wait to take action and upgrade their ELDs and telematics to 4G LTE. In addition to connectivity issues, microchip supply challenges could cause a delay to critical parts required to make these upgrades. As a result, fleets that don’t take action now could face an emergency situation in the near future.

Let’s take a look at why and how you should upgrade your fleet to 4G LTE technology.

The 3G sunset will finish over the next few months at many large U.S. carriers—has your fleet made the transition? Click To Tweet

4G Lifespan and Benefits

Cellular connectivity has evolved over multiple generations. In the 1980s, 1G networks provided analog, voice-only services with 2.4 Kbps data speeds. 2G networks enabled SMS and MMS messages with a maximum speed of 50 Kbps. And 3G paved the way for video calling and mobile internet with a 384 Kbps moving data limit.

4G LTE networks ushered in a new era of capabilities with 500x greater speed than 3G networks. For example, moving vehicles can access rates of 10 Mbps (10,000 kbps). The 20 MHz bandwidth sector also has a peak capacity of 400 Mbps, translating to more available bandwidth per unit of geographic area, as well as greater availability.

While 5G networks are rolling out across the country, these networks aren’t likely to replace 4G LTE in the same way that 4G replaced 3G. Rather, 5G is building on 4G using updated radios and software to improve throughput while sharing capabilities. As a result, 4G LTE networks aren’t likely to phase out for at least another ten years.

These advances have numerous benefits for trucking:

• Extended Coverage – 4G LTE networks have greater coverage in rural areas with better network reliability than 3G.
• Faster Speeds – 4G LTE networks have faster data speeds and lower latency when initiating new connections.
• Compatibility – 4G LTE networks are more compatible with new technologies and, in many cases, have a lower long-term cost.
• Video Capabilities – 4G LTE networks enable higher data speeds that support real-time video, such as Powerfleet Vista.

The rise of 4G LTE networks also comes amid a surge in new fleet telematics technologies. For example, asset tracking devices offer advanced power management with solar panels, supercapacitors, and long-lasting primary batteries. And camera technologies provide high-definition images, providing visual proof of road and cargo conditions.

New sensors also provide real-time data showing door status (open/closed), environmental conditions in the cargo area (temperature, humidity, or shock), and the load status of trailers. The result is more accurate billing and evidence to support or deny claims, which in turn helps improve customer satisfaction and retention.

How to Migrate to 4G LTE Solutions

Many trucking companies are aware of the upcoming 3G sunset but still haven’t finished evaluating technology providers. Others have no budget to acquire new technologies or remain hopeful that carriers will push out their sunset dates. Some companies are even switching carriers hoping that the new one will have a later sunset date.

There are a few things to keep in mind when upgrading your devices:

• Identify your essential requirements, such as battery life, environment, security, voice support, throughput, and cost. Each device has different capabilities, ranging from simple sensors to telematic hubs.
• Assess how the upgrades might impact other technologies, such as your fleet management solutions. In addition, consider whether you’ll need training and support for dispatchers, customer support, and other personnel.
• Determine if you want to access new technologies, like Bluetooth, solar power, or video solutions. In many cases, adding these features during an upgrade is an excellent way to level up your capabilities without a lot of added cost.

In addition to technology selection, you should have a technical migration plan in place—even if you have a small fleet with few drivers. For example, you need to catalog how many legacy 3G devices are in the fleet, archive your legacy data, and coordinate the shipping, receiving, and installation of the new telematics devices across your fleet.

The actual installation takes between 15 and 30 minutes per device. Of course, you must also ensure that drivers, dispatchers, and managers know how to use the new devices to avoid any miscommunications. As a result, you may need to budget time for a training session for these individuals and ensure that they are ready when the new solutions go live.

Consider Partnering with an Expert

The 3G sunset is imminent, and planning a large-scale deployment can be stressful on short notice. At this point, the easiest option for most fleets is working with an experienced partner that can help select the proper devices, plan out a deployment, and provide all of the extra installation and support that you need to get up and running on time.

Powerfleet provides a broad range of 4G LTE-compatible solutions across all asset types, from intermodal equipment to in-cab solutions to trailer and reefer to cargo visibility. With over 20 years of experience in telematics, we have helped transition customers from analog to 2G and 2G to 3G and understand the unique challenges these processes present.

Powerfleet’s team approach can help you devise the best plan to update your fleet, while our implementation team can walk you through the upgrade/rollout (e.g., uninstall and install) process. We also design, develop, and manufacture a wide range of product options, providing you with the flexibility to address every need with one provider.

The Bottom Line

3G networks have shut down across the U.S., paving the way for next-generation 5G networks with better speeds and connectivity. As a result, fleets using 3G ELDs and telematics are experiencing a loss of connectivity until they upgrade to 4G LTE-compatible devices. These newer devices can help not only restore connectivity, but boost performance and asset visibility.

Powerfleet has over 20 years of experience in logistics telematics with more than 125,000 devices in the field, spanning in-cab ELDs, reefers, containers, chassis, tankers, flatbeds, and much more. With experience transitioning from analog to 2G and 2G to 3G, we understand the unique challenges of implementing devices when you cannot stop operations.

Contact us to schedule a free consultation and learn how we can help ensure a smooth transition.

Drivers are the lifeblood of any trucking business. According to a 2021 ATRI report, driver wages and benefits represent a marginal cost of about $0.74 per mile or 45% of the total marginal cost per mile. Meanwhile, the ATA expects driver shortages to rise from 80,000 positions to over 160,000 jobs by 2030, driven by retirements and growing demand.

At the same time, the cost of mistakes has never been higher. The FMCSA reckons there were 155,585 large truck and bus crashes, 76,705 injuries, and 4,751 fatalities in 2020. According to the ATRI, the average jury verdict from a fatal trucking accident rose from about $2.3 million to nearly $22.3 million between 2010 and 2018—a 967% increase.

Let’s take a look at four ways to keep drivers safe and happy to minimize turnover while maximizing safety.

Drivers are the lifeblood of every trucking business—and it can be tricky to balance safety and morale. Click To Tweet

#1. Double Down on Training

The best way to maximize safety without hurting morale is to build a safety-first culture with a robust driver education and training program. For example, businesses should have reasonable expectations for delivery times, managers should invest time and effort in proper training, and drivers should default to safe behaviors.

Some good questions to ask include:

• Are new hires familiar with all of your safety policies?
• Does everyone have access to training documentation?
• Do you regularly check for compliance with these policies?
• Is there documentation in place to prove training took place?
• Are you using modern technology to make training effective?
• Do you monitor and retrain drivers that exhibit unsafe behavior?

It’s also essential to provide ongoing reviews and retraining when necessary. According to a 2015 PIT study, drivers that receive ongoing reviews after their training show an eight to 15 percent improvement over those that do not. Those that didn’t receive follow-up reverted to their original driving habits within two months.

#2. Update Your Telematics

Telematics play a vital role in fleet safety by monitoring everything from driver behavior to engine performance. But, unfortunately, many businesses leverage little more than standard Electronic Logging Devices (ELDs) with GPS capabilities. Even worse, some fleets are still using legacy 3G networks that will sunset this year, which can cause significant disruptions.

The FCC notes that 3G sunsets are already happening:

• AT&T announced that it would finish shutting down its 3G network by February 22, 2022.
• T-Mobile announced that it would finish shutting down Sprint’s 3G CDMA network by March 31, 2022, and Sprint’s 4G LTE network by June 30, 2022. It also announced it would shut down T-Mobile’s 3G UMTS network by July 1, 2022, but has not yet announced a shutdown date for its 2G network.
• Verizon announced that it would finish shutting down its 3G network by December 31, 2022.

In addition to upgrading to 4G LTE networks, fleets should consider investing in new capabilities. For example, Powerfleet’s in-cab ELD compliant solution goes beyond regulatory compliance to deliver real-time position reports, engine performance information, two-way communication with drivers, and full TMS integration.

Fleets can also leverage telematics across other assets:

• Dry Vans – Remotely determine load status, monitor cargo conditions (e.g., temperature, humidity, or pressure), and detect when doors are opened or closed. With Powerfleet’s solutions, you don’t need to worry about external power sources because solar capacitors and long-lasting batteries provide years of maintenance-free performance.
• Reefers – Remotely manage the reefer engine, alarms, and sensors without the trailer, monitor and set temperatures, and initiate trip needs, like defrost. These capabilities help fleets adhere to FDA Food Safety Modernization Act (FSMA) rules and meet customer quality control expectations. For instance, Powerfleet’s solutions feature cold chain monitoring solutions with dual-mode control across multiple zones, along with two-way command and control.
• Chassis – Track the chassis location across internal fleet and intermodal venues while detecting bare, mounted, loaded, and other statuses by measuring weight. In particular, Powerfleet’s chassis solutions feature advanced sensors that detect when a container is mounted and dismounted from the chassis, providing hard proof to back up billing disputes.
• Containers – Detect the location and load status of containers from the yard until they reach the final destination, enabling you to reduce cycle times and maximize utilization. Powerfleet’s container solutions even provide real-time weight sensors that eliminate the need for manual yard checks and provide an added level of visibility.
• Cargo – Monitor cargo with cameras and sensors to maximize visibility and efficiently analyze claims.

Implementing best of breed telematics solutions across your fleet can help maintain safety with drivers as well as equipment. Of course, the right software is critical to translate these data points into actionable intelligence. For example, Powerfleet provides an easy-to-use dashboard that aggregates these data points and makes it easy to do everything from tracking fleet assets in real-time to accessing KPIs that can help fleets spot trends and patterns to address unsafe processes or behaviors.

In addition, Powerfleet’s telematics integrate with an easy-to-use cloud-based platform where you can access actionable insights. The platform also integrates with third-party systems, such as TMS or ERP systems for customized analysis and KPIs.

#3. Adopt Dash Cameras

Dash-cams augment telematics data with visual evidence to enforce safety policies, exonerate drivers in accidents, and aid security and theft recovery efforts. For example, Powerfleet Vista delivers real-time high-definition video from road and driver-facing cameras that managers can access through an intuitive interface from anywhere in the world.

Powerfleet Vista adds real-time visibility to your fleet assets. Source: Powerfleet

Dash-cams have a mixed reputation among drivers, making their buy-in essential for success. Before installing dash-cams, managers should clearly explain why they’re necessary and how you’ll use them. In particular, it’s vital to explain that managers will never “spy” on drivers. Then, allow drivers to voice any concerns and ask questions.

#4. Start Incentive Programs

Research shows that incentive programs are more effective at changing behavior than disciplinary programs. For example, one study found that an electronic board praising hand-washing was 90% effective within four weeks compared to the 10% effectiveness of cameras and warning signs showing the dangers of not washing hands.

The data from telematics solutions opens up the door to new possibilities. For example, fleet managers can see the number of times drivers harshly brake, suddenly accelerate, or speed. While most companies penalize or retrain offenders, a better approach is building a safety incentive program that encourages safe driving behavior.

A common approach uses telematics-powered safety scorecards. These scorecards might include speeding, attendance, scheduling, near misses, seatbelt usage, idle time, and driving records. If drivers meet specific criteria, they may be eligible for cash bonuses, vacation time, paid lunches, or other desirable incentives.

The Bottom Line

The balance between fleet safety and driver morale is critical to the success of any trucking business. By building a culture that respects and values safety, you can minimize safety incidents and more easily defend the company against nuclear lawsuits if a fatal accident happens.

Telematics are key to unlocking many of these benefits. If you’re looking to upgrade your telematics, contact us for a free consultation or browse our product catalog to learn more.

The trucking industry has experienced several challenges over the past few years, including a global pandemic, supply chain issues, and a chronic driver shortage. Unfortunately, many of these problems remain moving into 2022, while a geopolitical crisis in Ukraine could introduce further supply chain and fuel price volatility to the market.

Let’s take a look at six trucking trends and proactive steps that every fleet should take to prepare for them.

The trucking industry has experienced several challenges over the past few years—here's what to expect in 2022. Click To Tweet

#1. Mergers & Acquisitions Heat Up

Mergers and acquisitions (M&A) in the transportation and logistics industry soared in 2021 thanks to record earnings, low interest rates, and a strong stock market. In addition to the strong financial incentive, many fleets are looking to grow from TL to LTL or vice versa to pursue a more holistic strategy and better compete in the market.

Other recent M&A drivers include:

• Supply chain issues have made it challenging for fleets to expand through organic growth, forcing them to consider M&A opportunities to meet growing capacity demands.
• Retailers are acquiring fleets to create private fleets that don’t suffer from the same bottlenecks and volatile pricing as contract fleets, guaranteeing deliveries and stabilizing prices.

While interest rates will almost certainly rise and the stock market has fallen in 2022, the ongoing supply chain crisis, increasing freight demand, and the desire for economies of scale could overcome higher financing costs and drive further consolidation. Financial buyers interested in market fundamentals are also bidding up deals.

#2. Technology Drives Greater Efficiency

Technology continues to drive change across the logistics industry. According to Gartner, half of global e-commerce businesses will invest in real-time transportation visibility platforms, artificial intelligence, and advanced analytics capabilities by 2023 or 2024.

Telematics and cloud computing will enable businesses to aggregate data from multiple sources and improve supply chain visibility. For example, technology will focus on improving customer experience by showing an accurate order status, preventing shortages and backlogs, and enabling businesses to visualize data to make better decisions.

• Driver Safety – Telematics and in-cab video can track speed, harsh braking, sudden acceleration, and other events to better assess safe driving habits. Using this data, fleets can retrain unsafe drivers to prevent costly accidents.
• Driver Retention – Telematics can help improve the driver experience by minimizing detention time and improving communication, while road-facing cameras can minimize risk by providing evidence to exonerate them in accidents.
• Fleet Tracking – Trailer tracking technologies make it easy to see the location and load status of fleet assets, while intermodal insights can help coordinate pickups and drop-offs to maximize efficiency.
• Right-Sizing & Cost Savings – Telematics, sensors, and cameras can measure asset utilization to help make right-sizing decisions that maximize profitability. At the same time, location data can help minimize detention times and improve turnaround times.

Powerfleet provides a range of telematics solutions—bumper to bumper. Our logistics telematics, cameras, and sensors can help with ELD, FSMA compliance, and other regulations while providing complete fleet visibility to dispatchers and operations managers. Using these solutions, fleets can make data-driven decisions that maximize operating ratios and keep them running efficiently.

#3. Data Becomes More Accessible

The best telematics data in the world isn’t beneficial if it isn’t accessible. Effective telematics platforms aggregate data across an entire fleet and compute key performance indicators (KPIs) that enable data-driven insights. Increasingly, they’re leveraging machine learning and artificial intelligence to derive insights from ever-growing data sets.

Powerfleet provides at-a-glance KPIs in its platform. Source: Powerfleet

In addition to translating telematics data into insights, fleets are turning toward telematics providers that offer open APIs to integrate data with their TMS and ERP solutions. For example, Powerfleet’s hardware platform devices and sensors deliver data to cloud-based portals and integrate with TMS and ERP systems through open APIs.

#4. Fuel Prices Will Be More Volatile

The Energy Information Administration (EIA) projected that fuel prices would fall in 2022 and 2023 amid slower demand growth. However, these projections came before Russia’s invasion of Ukraine, which could have a lasting impact on fuel prices. After all, Brent crude oil prices have already soared past $100 per barrel since the conflict began.

The EIA’s original fuel outlook for 2022 and 2023. Source: EIA

Fuel is the second-largest expense behind labor for fleet operators, meaning it significantly impacts profitability. While fleets have no control over fuel prices, there are several actions they can take to improve fuel efficiency through better driving habits, proactive maintenance, efficient route planning, and other strategies.

Telematics are essential to achieving better fuel economy and mitigating higher costs. For instance, fleets can save thousands of dollars per truck each year by limiting excessive idling and reducing maximum speed limits. These thousands of dollars can quickly add up when applied to even a modestly-sized fleet.

#5. Labor Shortages Will Worsen

Labor shortages have been a problem for the trucking industry for the past several years. According to the American Trucking Association (ATA), the nation faces a shortage of about 80,000 truck drivers. The industry group believes that the figure could surpass 160,000 by 2030, thanks to an aging workforce and fewer younger drivers taking up trucking careers.

Many of these problems are solvable by addressing turnover rather than bolstering recruiting—although recruitment remains a critical area of focus. After all, annualized turnover at carriers with more than $30 million in annual revenue is over 90%, according to Trucking Info, while even smaller carriers have a 75% turnover.

Telematics can help minimize driver turnover by keeping them safe with road- and driver-facing cameras, reducing detention times, eliminating paperwork, and improving two-way communication. In addition, telematics are instrumental for building safe driving reward programs and other incentives to keep drivers motivated and minimize risk.

#6. Telematics Will Unlock More Benefits

Telematics have become vital tools to improve safety and efficiency. While many fleets use GPS tracking and other basic solutions, new innovations could help unlock even more benefits to keep drivers safe and productive while maximizing fleet productivity.

Telematics can help in several ways:

• Keep drivers safe with in-cab cameras. In-cab cameras can help drivers improve their habits, protecting their employment and enabling them to qualify for rewards through driver safety incentive programs. Fleets can also use footage to educate drivers about on-road safety.
• Reduce wait times and improve capacity. Many drivers face extended wait times at shipping and receiving facilities, cutting into their drive time, earnings, and efficiency. Telematics can provide accurate arrival times and load status to help dispatchers maximize drive time.
• Cut out paperwork and manual processes. Trailer tracking technologies make it much easier to locate and manage trailers and other assets in the field, saving drivers time and improving overall efficiency. In addition, sensors can provide real-time temperature updates without driver actions.
• Improve two-way communication. Two-way messaging tools and vehicle tracking vastly improves communication between drivers and dispatchers. If any issues arise, drivers aren’t dreading the work ahead and the problems can be easily solved on both ends.

The Bottom Line

The trucking industry faces numerous challenges coming into 2022, from supply chain issues to the Russia-Ukraine conflict. Fortunately, there are several strategies that fleets can use to proactively address these challenges, including the use of telematics.

If you’re interested in adding telematics to your fleet, contact us to schedule a free consultation and learn how we can help you meet 2022’s challenges.

Warehouse operations have become increasingly complex with the rise of e-commerce, next-day shipping, and on-demand storage capacity. Of course, the COVID-19 pandemic accelerated the transition to e-commerce and put further strain on the system, leading to a critical shortage of warehouse space across the country.

Let’s look at four strategies that you can use to boost warehouse efficiency.

Technology plays a central role in helping improve efficiency at warehouses—we look at the most impactful investments. Click To Tweet

#1. Manage Inventory Visibility

Modern warehousing requires a high level of inventory visibility to maximize available space and ensure on-time deliveries. For example, the Port Authority of New York and New Jersey built a database of unused warehouse space to copy with seasonal spikes in demand (e.g., holidays) and unexpected disruptions (e.g., COVID-19).

On a warehouse level, Warehouse Management Systems (WMS) incorporate IoT data points to track inventory in real-time as items move from receiving to shipping. In addition, integration with external systems can keep shippers and customers up-to-date with the latest information, enabling real-time notifications of any delays.

Finally, inventory visibility goes hand-in-hand with Vehicle Management Systems (VMS) that control safety and maximize productivity. Powerfleet’s telematics solutions can help warehouse managers track operator performance and asset utilization. That way, you can reward top employees, retrain underperforming employees, and right-size fleets.

#2. Properly Maintain Equipment

There’s nothing that slows down a warehouse faster than malfunctioning equipment. For example, a broken dock door or dead forklift can force a production slowdown and delay deliveries. Even worse, a faulty forklift could lead to costly product spills or damages. These take precious time to clean up and result in lost inventory.

Of course, faulty equipment can also create safety hazards that lead to injury or death. For example, OSHA estimated over 8,140 severe injuries and 79 deaths from forklifts alone in FY2019. These injuries lead to an immediate shutdown of operations and could trigger significant fines and penalties—particularly for repeat offenders.

Powerfleet’s electronic checklists make it easier to identify problems. Source: Powerfleet

Proactive and preventive maintenance are the best ways to avoid these problems. For instance, our industrial telematics provide an electronic safety checklist for each operator at the beginning of their shift to identify potential defects. Telematics also combine real-time data with machine learning to predict when maintenance issues may occur.

#3. Implement Vertical Space

Many warehouses need to expand as a business grows. Rather than horizontal expansion, managers should look vertically to grow their footprint cost-effectively. For example, taller storage units and the right equipment can help fit more inventory in the same footprint, avoiding the need to expand and reducing travel distance.

Lean inventory practices can further improve efficiency. While inventories must never run dry, excess inventory makes it hard to efficiently move products in and out. Managers can strike a balance by reducing safety stocks and encouraging suppliers to deliver smaller quantities more frequently, resulting in a smaller amount of overall inventory.

Analysis of industrial vehicle patterns through telematics solutions can provide insights to high traffic areas of the warehouse and could help identify areas that may need to be re-organized to optimize for inventory accessibility and streamline operations while increasing safety.

#4. Leverage Technology

Telematics ensure regulatory compliance, automate safety, lower total cost of ownership, and provide complete fleet visibility and management.

Telematics sensors and camera systems continuously collect raw data. For instance, you might outfit each forklift with a GPS device that reports its location throughout the day or an accelerometer that detects unsafe driving behavior. Meanwhile, cameras record everything in real-time to provide a valuable record in the event of an accident.

Telematics software converts these raw data points into actionable insights. For instance, Powerfleet IQ makes it easy to analyze forklift utilization levels across locations and adjust allocations by downsizing, purchasing new equipment, or transferring equipment. And, the same system provides insight into driving behaviors across the warehouse.

Warehouse managers can use these insights to improve safety and productivity:

• Enforce Certification: Driver sign-in and safety checklists ensure that uncertified drivers cannot access forklifts, while safety checklists help comply with OSHA regulations. Powerfleet even lets you customize checklists for drivers in training.
• Better Training Videos: Forklifts with video recording devices produce valuable training videos showing real-life examples of completing specific tasks in a warehouse, as well as examples of good and bad behaviors.
• Refresher Training: Sensors that monitor speed, detect impacts, and track other incidents can alert managers of unsafe driving. That way, you can quickly provide refresher training to adhere to OSHA regulations and minimize costly safety incidents.
• Reduce Wear-and-Tear: Speed limiters and other technologies prevent speed and abuse with electronic throttles, extending the lifetime of vehicles and tires. At the same time, telematics software enables more intelligent maintenance schedules.

Since they provide so many benefits, telematics have a short payback period and a high return on investment, making them a smart choice for warehouses looking to improve safety and efficiency.

Don’t Forget About Safety

Warehouse efficiency shouldn’t come at the cost of safety. For example, increasing forklift speed limits and forcing overtime can provide a temporary boost in efficiency, but these efforts could have an adverse impact on workplace safety. As a result, warehouse managers should ensure that they’re optimizing for both efficiency and safety.

There are many ways to improve safety:

• Physical Barriers: Separate forklift traffic from other workers where possible, or even better, limit aisles to workers on foot or forklifts only. In addition, consider physical barriers between workstations and forklift aisles and restrict the use of forklifts near break rooms, cafeterias and exits.
• Driving Behavior: Our forklift telematics can monitor driver behavior, enabling managers to take appropriate action to address problematic behaviors. Meanwhile, you can incentivize good driving behavior to encourage drivers to prioritize safety as much or more than they prioritize efficiency.
• Safety Technology: We provide a range of solutions to improve forklift safety and minimize the risk of accidents. For instance, the Forewarner Sideliner LED projects a bright LED onto the floor, alerting pedestrians of an oncoming forklift regardless of ambient noise.

These technologies can minimize safety incidents and enable forklifts and people to work at maximum efficiency. In addition, they are relatively inexpensive with a quick payback period, making them an attractive investment for warehouses.

The Bottom Line

Efficient warehouses minimize costs, keep employees safer, and maximize customer satisfaction through improved operations.Technology is central in maximizing warehouse efficiency, from telematics to other technology such as sensors and cameras. Fortunately, these technologies make it easy to realize efficiency gains, resulting in improved safety, lower costs, and happier customers and employees.

If you want to deploy telematics to improve your warehouse’s efficiency, browse our product catalog or contact us today to schedule a free consultation.