DHL Supply Chain has taken delivery of its first Tesla Semi, marking a significant step forward in its strategy to scale up heavy-duty electric vehicles across North America. The company confirmed that the first unit is now fully operational following an extensive pilot programme that tested the truck on real freight routes in California.
The Tesla Semi was deployed from DHL’s Livermore facility, where it completed more than 5,000 km of live operations with customer freight. During the testing phase, the vehicle handled up to 34 metric tonnes of cargo and achieved a 625-km single-charge run while fully loaded. DHL reports that the truck averaged 1.72 kWh per mile under load, reinforcing its potential for both emissions reduction and energy efficiency.
With a range of up to 500 miles, the vehicle has moved into daily operation and currently completes around 100 miles of freight activity per day. According to DHL, the Semi requires charging approximately once per week due to the relatively short-haul nature of the current route.
The company estimates that each Tesla Semi introduced into service can reduce greenhouse-gas emissions by approximately 50 metric tonnes per year. The move is part of DHL’s broader fleet strategy, which includes more than 150 Class 8 electric trucks already operating in North America.
Other Logistics Operators Turning to the Tesla Semi
DHL is far from alone in exploring battery-electric heavy trucks. Several major logistics and freight operators have placed orders or begun pilot deployments of the Tesla Semi. UPS has reportedly ordered 125 units, while PepsiCo and its Frito-Lay division remain among the largest early adopters with around 100 trucks reserved. Food-distribution giant Sysco, brewer Anheuser-Busch and retailers such as Walmart have also committed to the vehicle. In the freight sector, operators including WattEV and Saia have taken delivery of initial units for commercial trials. The growing spread of orders across parcel carriers, retailers, manufacturers and trucking-as-a-service providers underlines a wider shift toward electrified long-haul operations across the logistics industry.
DHL plans to further expand its electric heavy-duty fleet in 2026, aligning with Tesla’s expected increase in production volumes. The company says the deployment of the Tesla Semi supports its long-term environmental goals and reflects growing customer demand for sustainable freight solutions.
As one of the world’s largest contract logistics providers, DHL Supply Chain’s endorsement of the Tesla Semi represents an important milestone for the adoption of electric heavy-duty trucking – a segment that many in the industry see as critical to realising net-zero supply chains.
Parcels, planeloads, and packed shipping containers are what people typically associate with DHL Group. However, this only scratches the surface of what the company delivers throughout the year. Here are just five of the most extraordinary shipments the global market leader in logistics handled in 2025.
Rare Antelopes Go Home
13,000 kilometers for survival: In February 2025, DHL transported 17 mountain bongo antelopes from a conservation center in Loxahatchee, Florida, to a wildlife sanctuary on the slopes of Mount Kenya, Africa’s second-highest peak. These animals are descendants of mountain bongos relocated from Kenya in the 1970s. Today, after decades of poaching, habitat loss, and forest degradation, the species is critically endangered, with fewer than 100 surviving in the wild. To ensure the Florida bongos’ safety and comfort on their journey, DHL provided a dedicated flight equipped with custom-built crates supplied by a wildlife protection organization. The animals received continuous care from a veterinarian and two bongo specialists. Their new sanctuary offers a secure environment where they can breed and thrive. Their offspring will one day return to the wild, reclaiming Mount Kenya’s forests as their natural home.
A Far-Traveled Helmet Meets Michael Schumacher
From Switzerland to Brazil, a helmet like no other embarked on a tour across continents in March 2025. On its journey, the helmet was signed by all 20 living Formula 1® world champions, becoming a unique piece of motorsport history. One signature was particularly moving: Michael Schumacher’s, the seven-time world champion who has withdrawn from public life since his severe skiing accident in 2013. His wife, Corinna, helped guide his hand to write his initials, “M.S.”, on the helmet – a gesture that resonated deeply with fans around the world. A replica of the helmet was later featured as a raffle prize to help fund the “Race Against Dementia” charity. Founded by three-time Formula 1® champion Sir Jackie Stewart, the organization funds research into prevention and treatments for dementia – a cause close to his heart after his wife’s diagnosis. Under strict security measures, DHL transported the helmet from Switzerland to the homes of multiple champions so they could add their signatures. The route included stops in Ibiza in Spain, London in the UK, and Brasília in Brazil.
Bear Sculptures on a Journey
When art goes on tour: In June 2025, 151 life-sized bear sculptures embarked on a journey of about 10,000 kilometers from Wustermark near Berlin to Singapore. Crafted from weather-resistant fiberglass, each sculpture stands about two meters tall. Known as the “United Buddy Bears”, this colorful art project was launched in Berlin in 2002 to spread a message of peace and tolerance. Every bear is painted by an artist from a different country, symbolizing that nation’s culture and identity. DHL oversaw the secure transport of these valuable artworks. Weighing a total of 37 tons, the shipment was packed into eight sea containers, loaded by crane onto trucks, and transported to the Port of Hamburg. From there, the bears began their sea voyage to Singapore, where they were displayed for two months, continuing their mission of promoting international understanding.
A Young Baboon Moves
An unusual passenger boarded a DHL flight from Bahrain to Djibouti, East Africa, in November 2025 – Saadoon, a young male baboon. He was found abandoned and in critical condition in Bahrain in 2024, at just three months old, in a country where baboons are not native. Saadoon was a victim of illegal wildlife trade. After more than a year of intensive care by an animal welfare organization, he needed an environment suited to his species. Djibouti’s climate and ecosystem offered exactly that. DHL flew Saadoon from Muharraq in Bahrain to Djibouti airport, where he was transferred to a specialized refuge near Djibouti City. Custom boxes, veterinary oversight, and an accompanying animal welfare representative minimized stress during the flight. Now living in a sanctuary tailored to his needs, Saadoon shares a new home with a female baboon, essential for social bonding among these intelligent primates. His new surroundings give him a chance to adapt and, hopefully, live freely one day.
South America’s Iconic Club Football Trophy
In November 2025, DHL delivered the iconic trophy for the CONMEBOL Libertadores Final, South America’s most prestigious club football showdown. The journey began at CONMEBOL’s headquarters in Luque, Paraguay, and ended in Lima, Peru, where the decisive match took place on November 29. Standing alongside Europe’s UEFA Champions League, the CONMEBOL Libertadores brings together the best clubs from across South America, each chasing the ultimate prize and the privilege to represent the continent at the FIFA Club World Cup. Known for its electrifying atmosphere and passionate fans, the final is a sports highlight watched by millions worldwide. As CONMEBOL’s Official Logistics Partner, DHL ensured the trophy’s safe and timely arrival. Roughly one meter in height, it traveled in a custom metallic case with a special security lock and was handled exclusively with gloves to preserve its flawless shine. Even sealed inside the case, the trophy sparked excitement – fans who spotted it often gathered to snap photos and share the moment. This year, Flamengo of Rio de Janeiro claimed the trophy after an unforgettable all-Brazilian clash against Palmeiras of São Paulo.
Supplying some of the world’s largest automotive and aviation brands with high-quality leather is a demanding business, requiring a robust forklift truck fleet capable of operating at peak performance in the harshest of industrial environments. Rushlift provides the full-support solution.
Scottish Leather Group is a family-owned, business built on supplying sustainable high-quality products to many of the world’s leading companies in the aviation, automotive, bus, coach and rail industries, as well as the luxury goods and furniture design sectors. High-profile customers include: Aston Martin, Polestar, Jaguar Land Rover, British Airways, Singapore Airlines, Ryanair and Irish Rail.
The business prides itself on its pursuit of operational excellence, with a combination of Six Sigma techniques, exacting sustainability standards and a strong emphasis on workplace safety – having achieved award-winning safety performance and RoSPA Gold recognition. Maintaining these high standards across their manufacturing and distribution sites near Glasgow demands a robust fleet of well-engineered forklift trucks capable of performing at peak under the most punishing of production environments.
Challenging conditions
“Tanneries are by their very nature some of the harshest working environments for mechanical equipment,” says Kelly Truman, Engineering Compliance Manager at Scottish Leather Group. “Our forklift fleet at our main production facility in Bridge of Weir, Paisley, and at our site near Glasgow, work three-shifts a day, moving hides between wet processes and loading vehicles. It’s tough work that can take a heavy toll on a vehicle as the chemicals involved in the manufacturing process are highly corrosive, requiring regular servicing of the fleet in order to keep them operationally effective and safe.”
Keeping to schedule and ensuring that production is uninterrupted is essential for Scottish Leather Group’s continued business success, as any failure to deliver on time can impact customer production lines. This responsibility places a heavy emphasis on the performance of the forklift truck fleet and each truck’s ability to maintain maximum uptime – these vehicles must be robust, reliable high-performers. And keeping them on top form over a three-shift day, ‘day-in, day-out’, requires regular servicing and a rigorous maintenance regime.
When it came to reviewing their materials handling fleet in the summer of 2024 Scottish Leather Group entered into a comprehensive tendering process which resulted in them placing an order for 18 new Bobcat forklift trucks with Rushlift, the national full-service provider of materials handling equipment.
“Rushlift proved their worth back in 2023 when they offered excellent support, supplying a fleet of powered pallet trucks to reduce manual handling across three of our sites and by arranging for a number of LPG powered counterbalance trucks on short-term rental,” says Kelly. “The maintenance and service support were first-class, so we knew we could rely on them – and the Bobcat product range was clearly fit for the task.”
High-spec, anti-corrosion
The order consisted of: Ten Bobcat G30E-7 four-wheel counterbalance trucks, fitted with triple lift masts, half cabs and load weight indicators, capable of operating with loads up to 3000 kg. Critically, the vehicles had to be specially adapted to protect them against the harsh, wet working environment of the tannery, which included a high-spec anti-corrosion paint applied to the bodywork and mast, along with extra-thick chrome plating and zinc coated chains. In addition, three of the trucks were fitted with a box rotator attachment, which were also treated with anti-corrosion paint.
But not all vehicles were destined for tannery use; other models were supplied for the less aggressive working environment of the distribution centre, and yard duties. Further Bobcat counterbalance models supplied included two G25E-7 with half and full cabs, a G35E-7 with a load handling capacity of 3500 kg, three BR16JW-9 reach trucks with integral sideshift, LED lights and panoramic mirror, and two heavy-duty electric counterbalance models, the B30X-7 and the B25X-7, both with half cabs.
All vehicles across the fleet were supplied complete with triple lift masts, 4th hydraulics and the latest safety equipment, including: blue spot safety lights for alerting pedestrians, full FTC Optafleet Telematics (pre-use safety check, fleet utilisation data and impact detection), and seat belt interlocks.
Full support
“Maintenance and regular servicing are incredibly important to us,” says Kelly. “That’s why we went for a leasing agreement with a full maintenance and support package from Rushlift.” This includes an increased frequency of Thorough Examinations based on the sites arduous conditions and environmental factors, via Rushlift’s partner Plant & Safety.
In addition, Rushlift have supported Scottish Leather Group in training some of their personnel on carrying out interim maintenance checks to ensure they identify any issues out with the regular servicing, maintenance and pre-use checks, to ensure maximum uptime in harsh environments.
Kelly concludes: “Over the past year, Rushlift has proven to be an exceptional partner, delivering a level of service and support that has consistently exceeded our expectations. From the outset, the Rushlift team has brought a wealth of industry knowledge, hands-on experience, and a proactive approach that has added significant value to our operations. Their ability to understand our unique needs and tailor their support accordingly has made a real difference – not just in terms of compliance and safety, but in the confidence and capability of our workforce.”
Rushlift is providing further ongoing support with floor cleaning machines and access equipment across all four of Scottish Leather Group’s sites.
Sensor specialist SICK has released the W12NextGen range of photoelectric sensors with enhanced detection capabilities, delivering intelligent usability even in harsh conditions. Building on the W12 series, the robust W12NextGen harnesses SICK’s innovation and sensor expertise to provide even greater precision, versatility and repeatability, with a range of new features.
SICK is continually innovating and the W12NextGen universal detection solution harnesses the company’s expertise, processing power and proprietary algorithms for superior performance across a wide array of industrial applications. In addition, the W12NextGen is the first SICK photoelectric sensor with a true digital twin and features new industry-leading Hybrid LED technology for better positioning, as well as state-of-the-art spot size recognition (SSR) for retro-reflective sensors. With easy setup and operation, and smart connectivity, it is enclosed in a rugged metal housing and built to last.
Easy to use
The W12NextGen provides outstanding detection performance even with high ambient light and reliable detection of critical objects. OpticalExperts facilitate detection at high speed, including very dark, shiny, flat, uneven, transparent or perforated objects, and those at different or difficult angles. Equipped with ClearSens for reliable detection of transparent objects and LineSpot for structured and uneven surfaces, W12NextGen sensors perform in even the most challenging environmental conditions, such as extraneous/high ambient light, shock, vibration or high/low temperatures. A new teach-in process, including foreground and background suppression, allows for fast setup on the device, while AutoAdapt technology allows the sensor to adapt to changing conditions.
Despite its advanced capabilities, the W12NextGen is simple to order, use and teach. The BluePilot user interface features a push-turn button for easy parameterization or SICK SOPAS software can be used via IO-Link for precise commissioning. An intuitive interface assists with fast installation and configuration, and a range of compatible accessories are available. W12 supports digitization with smart features and rich diagnostic & process data via IO-Link (temperature, distance, receiver level, alarm output, teach quality). Long lasting components and durable metal housing make the W12NextGen the most robust proximity diffuse sensor with TwinEye Technology, providing high chemical, thermal, and mechanical robustness.
Sensor Expertise
The iconic W12 has been one of the standout photoelectric sensors. Technological advances have led to an update that takes it to the next level, meeting the needs of OEMs and end users across industry. The robustness and reliability of detection provided by the W12NextGen and the extensive range of variants make it ideally suited to a vast array of sectors, including consumer goods, machine builders, material handling, and automotive OEMs and parts suppliers.
W12NextGen is a full range product family, featuring diffuse proximity, retroreflective, and through-beam sensors. Multi-mode sensors (WTM12, WLG12) provide universal application opportunities with one device, meaning a single inventory line and easy setup and commissioning. The ApplicationSelect mode enables hardly imagined ranges on low-remission objects and at large detection angles.
Applications for the W12NextGen sensor are endless, they vary from detecting water bottles in shrink packaging and detection of filled bottles in wet environments, to tear strip detection on transparent foil, objects in different detection ranges to prevent production line jams, detection of flat, uneven or glossy objects on conveyors, filling level of storage racks for material handling or material infeed, and monitoring of sorter tipping. Meanwhile, the W12NextGen’s digital twin enables OEMs and end users to model and develop whole production lines or machines, and it interacts with PLCs for design and virtual commissioning.
David Hannaby, SICK Portfolio Sales Manager, Presence Detection, says,
Exceptionally good, reliable and robust, the W12 family has led the market for decades. The W12NextGen photoelectric sensor takes an enormously popular and highly successful product to the next level. We have once again applied SICK’s decades of experience in customer-specific projects to innovative, high-end solutions that meet complex industrial requirements. The W12NextGen sensor harnesses technological progress in a single sensor to set new benchmarks in precision and reliability, and deliver uncompromising performance to the most challenging applications.
In the latest episode of the Logistics Business Conversations Podcast, host Peter MacLeod sits down with Sjoerd Eekelaar, Chief Customer Officer at Cargo on to discuss transforming supply chains.
On, to explore the transformative power of AI in the logistics industry. As businesses face challenges like driver shortages and sustainability, AI offers innovative solutions to optimize supply chains and enhance connectivity.
The logistics industry is on the brink of a digital revolution. With AI at the forefront, companies like Cargo on are leading the charge in creating fully connected supply chains. In this episode, Peter and Sjoerd delve into how AI is reshaping logistics, offering practical insights for businesses looking to embrace these changes.
Key Insights:
AI-Powered Supply Chains: Discover how AI is transforming traditional logistics processes, making them more efficient and sustainable. Overcoming Industry Challenges: Learn about the innovative solutions AI provides to tackle driver shortages and improve sustainability. Practical Steps for Businesses: Sjoerd shares actionable advice for companies looking to integrate AI into their operations, emphasizing the importance of digital innovation.
As the logistics industry evolves, embracing AI and digital innovation is crucial for businesses to thrive. This episode offers valuable insights into the future of logistics, providing listeners with the knowledge they need to stay ahead in a rapidly changing landscape.
Don’t miss this insightful conversation. Listen to the full episode below and subscribe to Logistics Business Conversations for more expert insights into the world of logistics.
Doncaster-based Hörmann Transdek has successfully supplied and installed a Vehicle-to-Ground (V2G) lift at Next’s South Elmsall distribution centre, near Wakefield. The lift supports a newly built warehouse extension designed to meet the retailer’s growing demand for online fulfilment.
Designed for modern, agile logistics, the V2G lift provides level-access loading and unloading for a full range of vehicles, from small vans to single and double-deck trailers. Its modular, free-standing design makes it suitable for both internal and external use, and its surface-mounted construction eliminates the need for pits or major groundworks, significantly reducing installation time and cost.
Next faced the challenge of installing a loading solution in part of the distribution centre that had a completely flat floor and no existing doors or loading bays. Hörmann Transdek’s V2G lift was the ideal answer, with its rapid delivery and flexible design allowing for installation within weeks. To accommodate the lift, a new opening was created in the warehouse’s external façade, and the lift was installed directly onto the internal floor slab, avoiding disruptive civil works.
The installed V2G lift has a 12-pallet, 5.3 tonne capacity and was supplied without cladding to make use of natural light within the warehouse. Its space-efficient design delivers a sealed, secure loading environment, aligning with Next’s operational and safety requirements.
Tristan Robbins, Project Manager at Next, commented,
The V2G lift from Hörmann Transdek has provided an efficient, flexible solution for a challenging area of the warehouse. The team delivered quickly, and the installation allowed us to maintain our timelines with minimal disruption. The result is a lift that has integrated seamlessly into our operation.
Key features of the V2G lift include:
LED traffic light system for safe coordination between vehicle and operator
Low-gradient loading ramp for safe equipment movement
Dedicated pedestrian walkway to separate personnel from vehicle movement
Safety curtain and light beam system to restrict access under the platform
Interlocked safety gates, fully compliant with UK/EU legislation
Suitable for ambient, chilled and freezer applications
V2G lifts are available in capacities from 4 to 14 pallets (4 to 12.5 tonnes) and include an MHE-compatible hydraulic bridge plate. For smaller commercial vehicles and vans, the optional ‘Vandango’ bridge plate ensures safe and efficient loading. Watch the video here.
NORD now offers digital twins for system development. Based on a myNORD configuration, it is now possible to request individually created drive systems as simulation models. This allows engineers to verify early in the planning phase whether the drive concept is suitable for the system. Virtual commissioning significantly reduces the project time – even for complex systems.
Since the publication of the FMI (functional mock-up interface) technical standard in 2010, it has become more and more common to work with simulation models in system planning. NORD DRIVESYSTEMS also uses data-based simulations for the development of its components and drive solutions. The system provider is now using this know-how to help its customers achieve greater efficiency and availability of its drive systems even in the planning phase by offering a digital service: With digital twins of its drives, NORD enables virtual commissioning.
Simple online configuration
Users can configure drive systems or components for their requirements as usual via the myNORD customer portal. They select components and their features such as performance, mounting options or outputs. Then, they can request a simulation model for the fully configured drive system. The process was developed by NORD in cooperation with the software company Machineering from Munich, which specialises in virtual commissioning.
Just a few weeks until actual commissioning
The advantage of these digital twins of the NORD solutions is the significantly faster availability of the entire system. The simulation models are inserted into a similarly simulated system. In this environment, the drive configurations can be extensively tested. If adjustments are required, they can be easily implemented based on the data. Errors can be remedied in the early stages of development, avoiding potential later damage. Only once the virtual drive system has been validated by the customer, it will be manufactured and delivered by NORD. As the drives are already functionally integrated into the system control at this point, actual commissioning is possible in a very short time. The overall process from configuration to commissioning is reduced from several months to only a few weeks.
High-efficiency
Virtual commissioning of drive systems is of special interest for any technically demanding solution. Therefore, NORD particularly focuses on components that play a decisive role in automating production processes. The manufacturer is kicking off the virtual commissioning with its range of high-efficiency IE5+ and IE4 motors, along with the corresponding gear units and frequency inverters. Simulation models will then gradually become available for other NORD product areas as well.
PROCare, British manufacturer of accessible wet rooms, bathrooms and adaptive kitchens, has significantly expanded its operational capacity and warehouse efficiency after implementing Forterro’s ERP and WMS solution Orderwise.
The business increased the number of daily orders it can process from 50 to 200+, boosted picking accuracy to 99%, and scaled its warehouse operations to 75,000 sq. ft. as demand continues to grow nationwide.
Founded in 2001 as a supplier of shower trays, PROCare now supplies adapted bathrooms and wet-room solutions to housing associations, local authorities and contractors across the UK. As its product range and customer base expanded, the company’s manual processes and legacy systems lacked the visibility and control required for sustained growth.
“Before Orderwise, processing 50 orders in a day was time-consuming. Now we’re regularly doing 200+ and handling far more products, all thanks to Orderwise making us more efficient,” said Adam Balmer, IT Manager, PROCare. “Orderwise just works – the prompts, the accuracy, the flexibility. It means we can keep growing without adding more people.”
Manual order entry and paper-based picking meant warehouse teams previously relied on memory to locate and select items. Today, every bathroom order is picked, labelled, and tracked individually using handheld scanners and guided walk routes, a transformation that has drastically reduced errors and driven improved customer satisfaction.
“Our picking errors are so low that even ISO auditors don’t believe us, we’re at around a 99% success rate,” Balmer continued. “Having that level of confidence across the warehouse is game-changing, especially when you’re supplying complex, high-value bathroom components.”
Since adopting Orderwise, PROCare has achieved: • 300%+ increase in daily orders processed (from 50 to 200+) • 99% pick accuracy across warehouse operations • Significant growth in online self-service orders through its trade portal • Seamless scaling of warehouse capacity to 75,000 sq. ft.
Tom Price, Director at Forterro, said: “PROCare is a strong example of how a modern, scalable ERP and WMS can unlock sustainable growth. By replacing manual processes and legacy systems with Orderwise, they’ve gained the accuracy, speed and control needed to support their expanding national footprint. As the company grows it has everything in place to scale with it.”
Konecranes has strengthened its lift trucks portfolio with the launch of its new electric reach stacker. Designed for high-intensity operations, the reach stacker delivers up to 16 hours of performance on a single charge, meeting growing global demand for eco-efficient material handling solutions.
With this new reach stacker, which made its debut to a select audience in Shanghai, China last month, Konecranes now offers customers a portfolio of fully electrified lift trucks. The reach stacker is now available across Asia-Pacific, Middle East and Africa as well as South America, with further expansion planned for Europe and North America during next year.
“Our focus remains on delivering lift truck solutions that drive efficiency for customers worldwide. With the introduction of the electric reach stacker, we now offer a comprehensive range of fully electrified lift trucks designed to optimize operations regardless of the location or handling need,” says Andreas Falk, Senior Vice President, Lift Trucks, Konecranes.
The Konecranes electric reach stacker is engineered for maximum productivity, offering up to 16 hours of operation, making it a perfect fit for demanding industries. Its fast-charging capabilities allows a full charge in just 1-3 hours, depending on battery size and charging power. Designed to deliver exceptional performance and reliability, it has significantly faster handling speed compared to diesel models. Key features include advanced safety systems, intelligent controls and durable mechanics.
From the start, it will be available in four robust high-capacity top lift models. The reach stacker boasts a short wheelbase and compact dimensions for effortless maneuvering and to accommodate high lifting capacities across all three container handling rows. With stacking heights of 5/5-high or 6/5-high at 8’6” / 9’6” containers, it promises optimal performance in intensive and challenging environments, ensuring that operations remain efficient.
“Our electric reach stacker features leading electric powertrain technology and intelligent control systems. With load-sensing hydraulics, faster charging and the safest and most spacious cabin the industry, it combines an optimized driving experience with advanced safety features ensuring exceptional productivity for various industries,” says Jeffrey Stokes, Director Product & Technology Management and Quality & Customer Satisfaction, Lift Trucks, Konecranes.
Like all of Konecranes’ Smart Connected Lift Trucks, the Konecranes electric reach stacker uses TRUCONNECT® to collect real-time data including battery charge monitoring, energy consumption, the amount of energy recovered from braking, as well as alarms, alerts and other diagnostics. All this data transmits securely to the yourKONECRANES customer portal to monitor and control the truck’s operational efficiency, productivity, safety and environmental impact.
This launch is part of Ecolifting™, Konecranes’ vision to increase its handprint – meaning the beneficial environmental impact that can be achieved with our product and service portfolio – while reducing customers’ carbon footprints. From eco-optimizing diesel drives, to hybridization and fully-electrified fleets, we will continue to do more with less.
A strong focus on customers and commitment to business growth and continuous improvement make Konecranes a material handling industry leader. This is underpinned by investments in digitalization and technology, plus our work to make material flows more efficient with solutions that support the decarbonization of the economy and advance circularity and safety.
To keep fleet vehicles moving and minimize costly downtime, fleet managers rely heavily on efficient logistics and dependable parts supply. Supply chain delays, global disruptions, and parts shortages can quickly turn routine maintenance into major operational setbacks, sidelining vehicles for days or even weeks. By using strong inventory strategies, predictive analytics, and reliable supplier partnerships, fleets can forecast demand, ensure fast repairs, and maintain on-time delivery performance.
The Cost of Fleet Downtime
Parts shortages significantly strain logistics operations by driving up expenses and limiting vehicle availability. Repair costs and upfitting have risen more than 20% since 2020 due to aging equipment, delayed shipments, higher labour rates, and costlier raw materials. Technicians often search local shops or repurpose parts from other vehicles, underscoring the need for better inventory planning.
One missed part delivery can cause service interruptions, shipment delays, and customer dissatisfaction. Direct losses include out-of-service vehicles, extended labour, rush shipping, and lost revenue. Indirect impacts include reduced logistics reliability and weakened business relationships.
Proactive Inventory Management
Logistics teams can prevent disruptions by shifting from reactive repairs to proactive inventory management. Modern inventory management systems (IMS) automate the tracking of spare parts, alert teams when stock runs low, and help forecast seasonal fluctuations. Key features include low-stock notifications, automated restock reminders, repair-frequency analysis, and purchasing-workflow integration. By improving visibility and eliminating manual errors, IMS tools reduce repair delays and help technicians respond quickly to maintenance needs.
Predictive Analytics for Parts Forecasting
Predictive analytics powered by telematics and historical repair data helps managers anticipate component failures and order parts in advance. By monitoring vehicle sensors and driver behaviour, fleets can:
Predict when components are likely to fail
Order critical parts early to avoid supply chain delays
Allocate inventory efficiently across service locations
This approach reduces emergency sourcing costs and unnecessary stockpiling. Fleets using predictive analytics report up to 15% improved vehicle uptime, better fuel efficiency, and reduced technician hours.
Tracking parts usage and repair patterns also highlights frequently used components and common points of failure. Many fleets build onboard emergency kits based on usage data so drivers can complete minor repairs in the field.
Strengthening Supplier Partnerships
Reliable supplier relationships are essential for maintaining consistent parts availability. Fleet managers should evaluate suppliers based on delivery consistency, flexibility, and quality. Diversifying vendors -using secondary or regional suppliers – helps cover spikes in demand and reduces vulnerability when supply chain disruptions arise. Transparent communication also strengthens forecasting accuracy and negotiation power.
Digital marketplaces expand sourcing options even further by allowing fast access to multiple vendors, including any auto parts seller capable of filling urgent gaps. Predictive insights give fleet managers lead time to secure alternative suppliers and negotiate favourable terms when traditional pipelines face delays.
Reliable parts supply is no longer just a maintenance function – it’s a strategic imperative for logistics leaders dedicated to efficiency, cost control, and uninterrupted fleet operations.
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