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Day: 11 March 2025

AI for Real-time Control of Industrial Trucks

Posted on by David Priestman

In the future, warehouse managers will increasingly be able to rely on artificial intelligence (AI) when it comes to optimizing material flow processes, incluidng real-time contraol of industrial trucks. At its tech showcase at the LogiMAT trade fair in Stuttgart, Linde Material Handling (MH) will demonstrate how this product vision works and is gradually becoming reality. The solution is based on NVIDIA’s powerful Omniverse AI platform, which uses a digital twin to collect, process and analyze vast amounts of data from warehouse operations in real time. This initiative aligns with Linde MH’s parent company, the KION Group, which recently announced a large-scale collaboration with NVIDIA, a leader in AI, and Accenture, an expert in digitalization, to take industrial automation to a new level.

In an area adjacent to Linde MH’s exhibition stand, a scenario will be staged that could be typical of the warehouse of the future – manual and automated industrial trucks working side by side in perfect harmony with the help of innovative AI technology. This development will be particularly advantageous for operators of large fleets. The integration of intelligent hardware and software, combined with substantial computing power, will guarantee transparency of every process within the warehouse, ensuring more efficient, reliable and flexible order processing through continuous simulation. “Machine learning and neural networks will enhance warehouse efficiency. Throughput will increase, both manual and automated fleets can be optimized and staff can be deployed more efficiently. This will lead to significant cost savings for companies,” says Ulrike Just, Member of the Management Board responsible for Linde MH Sales & Service EMEA. “As a technology and innovation leader in our industry, we are at the forefront of developing AI-based solutions. These solutions represent a significant breakthrough, aiming to enhance our customers’ competitiveness and ensure the long-term efficiency of their material flows. We are planning initial pilot projects with major customers, for whom the return on the investments involved will be particularly high.”

Real-time localization creates transparency

The first step in Linde MH’s strategy is to network manual industrial trucks. To this end, the intralogistics specialist is currently developing a real-time localization system that works both inside and outside the warehouse. It enables seamless tracking of each vehicle’s location using innovative, low-infrastructure ultra-wideband technology. An intelligent display provides drivers with navigation instructions and new or updated transport orders, with the system combining location data with vehicle data such as the steering angle. This allows routes to be adjusted in real time if, for example, there is too much traffic on a route, causing delays.

At some point, AI becomes indispensable

As warehouse operations become more complex, the optimization of routes and coordination of manual and automated industrial trucks places much higher demands on computing power. “When there are 100 or more vehicles to coordinate, it’s essential to utilize higher-level intelligence and hardware capable of handling such extensive data volumes,” explains Ron Winkler, Managing Director of the Digital Business Unit at Linde MH. “This is where the NVIDIA Omniverse platform’s AI comes in. It creates a digital twin of the warehouse, a virtual 1:1 replica of the physical environment.” In this digital twin, simulations can be run in fractions of a second – either to optimize routes and optimally coordinate AMRs and manual forklifts, or to achieve optimizations in existing warehouse layouts.

The key advantage is that solutions to changing warehouse conditions, such as new orders or inventory fluctuations, traffic congestion in certain warehouse areas, obstacles or overhanging loads, can be identified in real time, simulated in the digital twin and communicated back to the vehicle control system. For instance, if a truck arrives late, the system can automatically assign the nearest forklift equipped for unloading. To achieve this, the NVIDIA Omniverse platform digitally stores all physical data on industrial trucks (e.g., engine power, steering angle) and infrastructure (e.g., rack locations, routes, machine times). This virtual space then processes the constant stream of information coming from sensors, intelligent vehicle and infrastructure cameras, warehouse management software and vehicle control systems.

Simulation is the key

Intelligent camera systems, strategically installed throughout the warehouse infrastructure and on both manual and automated vehicles are used to track load carriers, AMRs and manual vehicles. They also provide real-time monitoring of loading and storage areas. The images captured by these systems are then interpreted and processed directly by the AI.

The showcase at Linde’s stand will demonstrate this in practice: A forklift driver transports goods to the receiving area using a Linde electric forklift. In the designated transfer area, a fully automated Linde pallet stacker then picks up the pallet for further transport into the warehouse. To seamlessly document and track materials and goods on the Omniverse platform, the manual truck’s mobile, intelligent camera automatically takes a picture of the load when the pallet is picked up and stores it in the system. Concurrently, the camera captures the entire environment, identifying people and obstacles and instantly adapting the vehicle’s behavior to the situation. The stationary cameras in the warehouse provide the system with information about the occupancy of the storage locations, while also detecting potential collisions with people, which would cause the trucks to reduce speed.

However, what if the forklift driver does not place the pallet precisely on the specified surface, as an AGV typically requires? Via the stationary cameras, the digital twin recognizes the pallet’s placement and directs the picking order to the Linde L-MATIC core. Thanks to the intelligent camera on the fully automated AGV, the AI detects the tilted pallet and determines a solution – in this case, the best approach to picking up the load. The cameras also identify problems such as cartons slipping or part of the load overhanging. In such cases, the AI concludes that the AGV should not pick up the load. The Linde L-MATIC core would halt and be reassigned to another transport order. Meanwhile, the AI calculates which manual guided vehicle is nearby to take over the transport task.

“By configuring a digital warehouse twin, any conceivable infrastructure and fleet configuration can be simulated in 3D and tested for efficiency,” explains Ron Winkler. “The AI can be continuously trained and refined. This sets the stage for a warehouse ecosystem that proactively solves challenges and keeps getting better and better.”

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Mobile Weighing Without Waiting

Posted on by David Priestman

As the uptake of autonomous solutions increases in warehouses, integrated mobile weighing specialist Ravas is rolling out its existing tried-and-tested technologies to embrace this growth.

An established player for many decades in the intralogistics sector with its renowned, award-winning weighing solutions, the integration of Ravas’ mobile weighing systems with automated vehicles such as AGVs and AMRs is smooth and logical, as the technology it uses is very similar to that deployed around the world in manual forklifts and other MHE.

In-motion weighing has many advantages, most notably eliminating the need for a separate weighing station. As autonomous trucks are not able to travel at the speeds attained by their traditional manual equivalents, a diversion to a static weighing platform can be quite time consuming. By eliminating this leg of the journey, the Ravas AGV solution captures the data en route, allowing goods to take the most direct path to their destination elsewhere in the warehouse.

Accurate Inventory Control

As with manual trucks, the weighing information gathered by AGVs and AMRs in the warehouse can be used to provide more accurate inventory control and to optimise data collection for real-time
decision-making. “The data collected could be for invoicing, shipping, or for legal-for-trade purposes,” says Rob Ruijs, Sales Manager OEM for Ravas Europe BV. “But we also see it as a tool to give 100% accuracy with order picking. With the extra control, the system will only clear the order line if the right amount is picked. It will notify the user – whether it’s automated or human – that the right amount has been picked and you can move on to the next one.”

Integration of the technology is seamless, and the weighing data gathered can be either communicated directly to the WMS, ERP or TMS, or stored within the AGV. Data can be transmitted physically via RS232 or CAB-456 cables or wirelessly via Wi-Fi, 5G or Ravas’ own RIS software. “We have multiple options, whatever data flow is required by the customer,” says Ruijs. “With our own R&D department here in Zaltbommel (Netherlands), if a customer needs something special which we don’t have at the moment, we can figure it out together and make the required solution. For example, in the cargo business we combine the weighing data together with technology from one of our dimensioning partners to assist with loading and reporting.”

Ruijs says Ravas can deliver a complete package for both existing and newly-developed AGVs, and whilst he works at OEM level, he says the technology can also be retro-fitted at a customer
site. “With automation, it’s more of a solution-based sales than just a typical off-the-shelf product. Between the three of us – the OEM, Ravas and the end customer – together we can make a
solution. As the system we use for AGVs is, fundamentally, the same as we use for manual trucks, should a customer need, for example, ATEX protection, then we already have that technology in
our range and the implementations, it’s just a question of applying the solution to a different type of vehicle.”

Sector Growth

Driven by labour challenges, the AGV and AMR sector is undergoing considerable growth, particularly in those regions where hiring humans is most expensive. “We see a growth in the automation markets due to labour costs and shortages, but also in how it can reduce downtime,” says Ruijs. “After all, unlike a human an AGV can run 24/7 without any breaks. Because we are innovators within the weighing market, we have been targeting that market actively since August last year, and the ball is really starting to roll.”

Ravas is well placed to capitalise on this growth, given the brand’s strong reputation, especially in Europe. “We have over 65 years of experience and we already have a proven product, integrated with all the OEMs, so our base within the market is there,” concludes Ruijs. “Furthermore, we have service personnel all around Europe, and in those countries where we don’t have our own people, we partner up with specialists. Ravas is doing well is because we are fully service orientated, which in our sector is sometimes even more important than just the purchase itself.”

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Handle and Load Cargo with Care

Posted on by David Priestman

Loading and unloading trailers and containers is an important stage in the supply chain, requiring skill and the right equipment if it is to be completed quickly and correctly, writes Wouter Satijn (pictured), Chief Revenue Officer of Joloda Hydraroll. Many companies continue to rely on forklift trucks and manual processes for loading and unloading goods, but this can lead to high instances of product damage and result in delays and financial losses that add up to more than you might think.

Industry estimates suggest that, on average, 2% of unit loads arriving at a distribution centre have some level of case damage. In some instances, this figure can rise as high as 11%. As logistics operations become more complex and time-pressured, businesses must take proactive measures to ensure goods are handled with care, transported safely, and arrive at their destination in perfect condition.

Common loading mistakes that lead to product damage

There are several ways damage can occur when loading and unloading goods. For example:
• Forklifts that are not properly aligned with pallets when lifting them can puncture loads or push them off the racks.
• Some operators may double-stack pallets that aren’t designed to bear extra weight. This can crush the pallets underneath – and the products within – and cause them to become unstable during transportation.
• Old, rotten, or otherwise compromised pallets that have not been inspected before use may also collapse under weight or when moved.

How to reduce product damage when loading

A combination of the following best practices, employee training, and the right equipment can all but eliminate the risk of product damage during the loading process:
1. Improve loading practices
Pallets should be loaded uniformly, with weight evenly distributed to prevent crushing or instability. Pallets should be regularly inspected for weaknesses and not double-stacked. Liquids should always be placed below dry goods to minimise the risk of contamination in case of leaks, while dunnage can be used to fill up any empty spaces, provide cushioning and prevent goods from shifting.
2. Ensure pallets are secure
Using the right wrapping method can significantly reduce damage. Wrapping should be firmly secured at the pallet base, then spiral upwards to ensure stability. A 360-degree wrap is needed two to three times over to cover the stack and secure the stock.
3. Choose the right containers
It’s important to select the right sized container to match requirements and that doesn’t exceed weight or size limits at any stage of the shipping process. Climatic changes that could affect the cargo should also be considered to protect products such as perishables from spoiling or deteriorating.
4. Keep the facility clean and tidy. A clutter-free warehouse or loading dock is a non-negotiable so that forklift operators have a clear path to manoeuvre safely. Designated areas for storage or waste should be assigned and adhered to for an efficient and hazard-free environment.
5. Regularly inspect equipment and processes
Routinely checking for signs of equipment wear and tear can prevent accidents, while regularly reviewing loading procedures help ensure employees follow best practices and adhere to safety protocols. It’s important that time is taken to check the container/ trailer, too – for structural damage, but also residues that could go on to contaminate the next load of goods.
6. Prioritise employee training
The biggest risks come from workers who might not feel confident they know how to operate equipment or perform tasks correctly. An effective training programme is key to ensuring safety and minimising product damage. Employees should receive regular refresher courses to ensure they remain up to date on safety procedures and equipment use.
7. Invest in the right handling equipment
Finally, ensure all equipment is well-maintained and fit for purpose and consider automated loading solutions that minimise manual handling. These systems can make the loading process far more efficient and cost-effective, while greatly reducing the likelihood of human error and forklift mishaps.

Goods are at risk of all kinds of damage, depending on how they are stored, how they are loaded, and how they are secured during loading. By providing employees with frequent training, conducting regular inspections, and investing in the right equipment and automation for the job, businesses can ensure efficient loading and unloading processes that protect more than their cargo – they can protect their employees and their bottom lines, too.

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Supplier Collaboration Value

Posted on by Keith McKinley

With cost cutting still very much at the top of the business agenda, companies across the world have already started creating improvement plans to tackle operational expenses, writes Simon Thompson (pictured), VP Northern Europe at JAGGAER.

Businesses are focusing on driving value through supplier partnership and are prioritising visibility of stock and procurement strategies optimisation. In fact, one typical business area that is usually seen as no more than a cost centre is procurement and, more specifically, the supply chain. As a result, savvy businesses are reassessing their approach to supplier relationship management, enacting measures that amount to a complete paradigm shift to transform this function in a value centre that can create long-term value as well as reduce costs.

Traditional cost-cutting strategies, that prioritise short-term savings and negotiating the lowest possible prices with suppliers, can backfire over time, potentially leading to quality issues that may escalate into expensive product recalls, customer dissatisfaction, and reputational harm. Strategic partnerships and collaboration within the supply chain can instead become an opportunity to create additional value that goes beyond simply reducing costs, allowing the procurement officer to consolidate spending or uncover shared efficiencies to encompass a range of key issues and benefits such as promoting sustainability, co-investing in innovation and finding new avenues to enhance customer satisfaction. These partnerships can help mitigate supply chain risk, improve resilience, foster digital transformation and facilitate regulatory compliance.

Collaborative procurement strategies

Effective cost management in supply chains therefore extends far beyond reducing raw material costs and covers every stage of the supply chain, from sourcing and logistics to inventory management and payment terms. That’s when collaborative procurement strategies come into play. These strategies are based on building trust and transparency, fostering beneficial partnership with the supplier with the aim of achieving cost saving without compromising quality. Open dialogue and transparency are at the core of this approach, allowing buyers and suppliers to collaborate openly, sharing objectives and creating mutual benefits. Sharing demand forecasts helps suppliers optimise production processes, minimising waste, lowering operational costs and reducing prices.

Key to achieving this transparency are real-time procurement platforms that grant visibility to both companies and suppliers and can also improve demand management and inventory needs synchronisation, prevent overproduction, as well as enabling more efficient resources allocation, production schedules and inventory management, ultimately reducing unnecessary costs. While it’s important for procurement to have visibility, trust is a two-way process and a sometimes overlooked component of supplier collaboration is committing to on-time payments. Consistently paying suppliers on time fosters trust, which can lead to improved payment terms or pricing advantages.

Thanks to these platforms it is also possible to enable Just-In-Time (JIT) processes. In fact, partnering with suppliers to implement JIT inventory systems can help minimise excess stock and storage costs, while ensuring timely delivery of goods. This is particularly relevant for industries handling bulky items, perishable goods, or material requiring strict temperature control, such as those managed within the cold chain. In the pharmaceutical sector, for instance, JIT helps reduce waste and improve efficiency by ensuring medicines or devices are ordered and delivered only as needed for production, significantly reducing the likelihood of having to deal with unused or out-of-date stock.

Efficiency gains

Conducting regular supplier relationship evaluations using scorecards provides another avenue for efficiency gains by identifying areas for improvement, uncovering potential cost-saving opportunities, and strengthening collaboration. These evaluations also offer a transparent foundation for discussions and renegotiations with suppliers and offer the opportunity to raise issues or share ideas for improvements such as a new supply route or material. Centralized platforms that automate transactions, facilitate communication, and provide advanced analytics allow businesses to identify inefficiencies and optimize procurement strategies. By leveraging intelligent technologies, companies can enhance decision-making, mitigate risks, and access diverse data sources, without overburdening internal teams or suppliers with excessive manual data entry and updates.

Procurement’s focus is shifting from cost control to driving value creation, and supplier collaboration is emerging as a pivotal strategy for achieving not only sustainable cost savings but also broader operational improvements. Success in this area hinges on building trust, ensuring transparency, and adopting a comprehensive approach that balances cost savings with other factors like quality, supplier diversity, long-term sustainability, and risk management. This approach relies on a strong data foundation across the entire source-to-pay process, supported by advanced spend analytics. With these tools, procurement leaders can develop and implement strategies that deliver significant value for both buyers and suppliers, while nurturing strong, cooperative relationships with every actor of the supply chain.

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