Smart Forklift Monitoring Project
CLIENT: FORGING-FOUNDRY SECTOR
Introduction
THE CLIENT has a fleet of forklifts from various manufacturers, most of which are leased. These forklifts, both electric and combustion-powered, perform critical functions in the plant, such as transporting finished parts, stockpiling raw materials, and more complex operations such as pushing equipment for machine setup.
Currently, its use is distributed across three daily shifts by different operators, without a standardized identification or control system.
Diagnosis of the Current Situation
Various problems have been identified in the intralogistics operation of forklifts:
- Lack of traceability
There is no system that identifies the operators assigned to each forklift, nor does it monitor routes, usage times, or operational metrics. - Rising costs
Annual maintenance has seen a sustained increase, largely attributable to misuse resulting from impacts or improper maneuvers, which directly impacts the cost of leasing. - Operational inefficiency
Inefficiencies are perceived both in routes and in the management of tool pushes, with no visibility or effective coordination between operators and work areas. - Security risks
Bad practices not only increase the cost of operations, but also pose a serious risk to staff safety.
Proposed Solution – Pilot Project
Intelligent Monitoring of the Intralogistics Process of an Electric Forklift
This pilot project proposes a comprehensive technological solution aimed at providing visibility and traceability, thereby improving safety and efficiency in the operation and maintenance of forklifts at THE CLIENT. To this end, an intelligent monitoring and control system will be deployed, based on the integration of advanced sensors, specialized software, and data visualization platforms.
Project Components
- Capture and analysis of operational data
Integration of a datalogger connected to IZURUN TECHNOLOGY’s CleverLoad® platform, tailored to THE CLIENT’S specific requirements.
Recording of key variables, highlighting the signal from the onboard triaxial accelerometer, capable of detecting impacts and abnormal behavior. - Identification of operators
Development of an authentication system based on RFID cards already used by THE CLIENT, integrated into the forklift’s electronics, allowing it to be started only after operator validation. - Indoor location system
– Precise location recording in case of impact.
– Path tracing for logistics analysis and optimization.
– Monitoring the use and location of tools on production lines. - Video capture in the event of critical events
Installation of onboard cameras that will record continuously, automatically sending the 5 seconds prior to a detected impact, using the CleverLoad® system as an analysis platform. - Prevention of run-overs
Implementation of an advanced pedestrian detection system that will directly affect the forklift’s movement control to prevent serious incidents.
Scope of the Pilot Project
The pilot will be implemented on a newly acquired electric forklift, provided by the leasing company. Once the solution’s effectiveness has been validated, its gradual rollout to the rest of THE CLIENT’s forklift fleet is planned.
The scope includes the supply and integration of:
- Monitoring software (CleverLoad®),
- On-board sensors and electronic components,
- Communications infrastructure,
- Professional installation, configuration, and support services.
IZURUN TECHNOLOGY, as the developer of the CleverLoad® suite and technology integrator, will lead the project, contributing its experience in high-value solutions for the industry.
Success Indicators – Project Objectives
- Security
Maintain the plant run-over rate at zero. - Reduction of maintenance costs
Reduce by 30% the number of misuse incidents that generate additional costs due to damage to forklifts, facilities, and auxiliary machinery. - Operational efficiency
Improve the efficiency of forklift use by 20%, especially for transporting and pushing equipment.
