RTLS Use-Cases for Warehouses: Optimizing Pallet & Forklift Operations
Guest blog by MHI Member Deeyook
In today’s fast-paced logistics environment, efficiency is key. Warehouses handling thousands of pallets and operating large forklift fleets face significant operational challenges. Real-Time Location Systems (RTLS) offer a powerful solution to optimize warehouse management, reduce costs, and streamline daily operations.
In this blog, we’ll explore two critical RTLS use cases—warehouse pallet management and forklift fleet optimization—and how innovative solutions are transforming the industry.
RTLS for Warehouse Pallet Management
Managing thousands of pallets efficiently is a complex task, particularly in large warehouses where misplaced pallets lead to operational delays and increased costs. Forklift operators often spend extra hours locating and sorting pallets, impacting productivity. Implementing an RTLS solution provides real-time tracking, significantly reducing search time and improving overall efficiency.
Key Considerations for Pallet Tracking
• Pallet Quantity: Each pallet requires a tracker, making it crucial to assess the total number of pallets to determine the number of tags needed.
• Movement Frequency: Since pallets are typically moved once per day, tracking their location on an hourly basis is sufficient to maintain visibility.
• Location Accuracy: Given that pallets occupy a 1m x 2m space, an RTLS solution offering one-meter accuracy or better ensures precise tracking.
• Storage Arrangement: Many warehouses utilize vertical stacking to maximize space, meaning an RTLS solution must account for multi-level storage.
• Infrastructure Requirements: Most warehouses already have Wi-Fi (Access Points), which RTLS solutions can leverage. With an optimal spacing of 20 meters between Access Points (AP), additional infrastructure costs are minimal. If existing AP coverage is insufficient, many RTLS solutions can compensate by using tags, keeping infrastructure investments low.
• Cost Drivers: The primary cost factor is the number of tags required, calculated based on the total pallet count. A good RTLS product should utilize existing Wi-Fi, significantly reducing infrastructure expenses.
By implementing an RTLS-powered pallet management system, warehouses can minimize pallet misplacement, reduce forklift working hours, and lower overall operational costs.
RTLS for Forklift Fleet Management
Forklifts are an essential asset in warehouse operations, but inefficient fleet utilization can lead to unnecessary costs. Many forklifts remain idle for parts of the day, and without proper tracking, warehouses often maintain more forklifts than necessary. RTLS enables real-time forklift tracking, helping warehouses optimize fleet usage and reduce expenses.
Key Considerations for Forklift Tracking
Forklift Quantity: Warehouses typically operate a two-digit number of forklifts, requiring precise tracking to determine utilization levels.
Movement Frequency: Unlike pallets, forklifts are in constant motion, necessitating real-time tracking with updates every second for effective fleet management.
Location Accuracy: RTLS technology provides sub-meter accuracy, ensuring precise tracking of forklift movements and usage.
Software Integration: A dedicated software platform is essential for monitoring forklift activity, identifying idle time, and optimizing fleet operations.
Infrastructure Requirements: As with pallet tracking, RTLS solutions utilize existing Wi-Fi, minimizing the need for additional infrastructure investments.
Cost Drivers: The primary cost factor for forklift tracking is the software, typically priced based on the number of forklifts being monitored. Infrastructure costs remain low due to an RTLS solution’s reliance on existing access points, with only minimal enhancements required when necessary.
By implementing RTLS for forklift fleet management, warehouses can eliminate operational inefficiencies that lead to delays, idle time, and unnecessary fuel or energy consumption. RTLS enables managers to monitor forklift movement, identify traffic bottlenecks, and detect underused or overburdened vehicles. This data empowers better decision-making around task assignments, route optimization, and maintenance scheduling. As a result, resource allocation becomes more balanced, workflows become smoother, and equipment lifespan is extended. Altogether, this contributes to measurable cost savings—not only by reducing downtime and labor waste but also by enhancing overall productivity and safety across the warehouse floor.
Why RTLS is a Game-Changer for Warehouses
Implementing RTLS solutions for both pallet tracking and forklift management provides warehouses with unparalleled visibility and efficiency. With the right RTLS technology, businesses can leverage existing infrastructure, reduce unnecessary costs, and enhance overall operational performance.
Ready to transform your warehouse operations? Contact us to explore how RTLS can streamline your logistics and drive productivity.
