How RTLS Reduces Operational Costs in Logistics Yards
RTLS for logistics yard operational efficiency – RTLS software, or Real-Time Location Systems software, can significantly improve warehouse yard operational efficiency in various ways, making it a valuable tool for businesses across industries. Here’s how:
Enhanced Asset Tracking and Utilisation in Logistics Yard
- Real-time visibility: Know exactly where your equipment, tools, and materials are located on the shop floor or warehouse through strategically placed sensors and tags.
- Reduced downtime: Quickly locate misplaced or missing assets, minimising search time and production stoppages with RTLS in factories
- Optimised utilisation: Identify underutilised equipment and redistribute tasks for better efficiency.
Streamlined Workflows and Improved Productivity in Warehouse Yard
- Optimised task allocation: Assign tasks to workers closest to the required resources, reducing unnecessary movement and wasted time using preventive maintenance scheduling.
- Paperless processes: Eliminate paper-based tracking systems with digital data collection through RTLS software.
- Real-time progress monitoring: Track work progress in real-time and identify bottlenecks for immediate corrective action.
Improved Inventory Management and Reduced Costs
- Accurate inventory levels: Gain real-time insights into inventory levels and locations, FiFo models, and minimise overstocking and understocking.
- Reduced shrinkage: Track high-value assets to prevent theft or loss.
- Optimised purchasing: Make informed purchasing decisions based on actual usage data.
Enhanced lone worker Safety and Security
- Lone worker monitoring: Ensure the safety of lone workers by tracking their location and movements in factories and warehouses
- Restricted access control: Limit access to certain areas for improved security and compliance.
- Emergency response: Quickly locate personnel and assets in case of emergencies.
Data-Driven Decision Making
- Collect and analyse data: Gather valuable data on shop floor activities, worker performance, and asset utilisation.
- Identify trends and opportunities: Analyse data to identify areas for improvement and optimise processes.
- Make data-driven decisions: Use data insights to make informed decisions about resource allocation, staffing, and overall operations.
Yard Space Occupancy Rate: This measures the proportion of available parking spots or storage areas currently taken up by trailers or containers.
Goal: To maintain an effective balance where the space is well-utilised (to maximise its value) while ensuring enough empty buffer space remains to prevent traffic congestion and operational bottlenecks.
Shunter/Yard Truck Productivity: This tracks the efficiency of yard drivers and vehicles by counting the average number of trailer moves or tasks completed per hour or per shift.
Goal: To maximise the productive working time of both the equipment and the labour force by minimizing unnecessary idle time and reducing non-productive “empty miles” (movement without a trailer).
Yard Inventory Location Accuracy: This is a measure of how closely the recorded location and operational status (e.g., loaded, empty, awaiting service) of all trailers and assets in the yard management system match their physical reality.
Goal: To achieve and maintain high accuracy to eliminate the need for manual searches, which saves time and ensures the correct asset is located for every task.
Preventive Maintenance in Logistics Yard Management
In a modern distribution centre, the conveyor system is the central nervous system. When a belt slips or a motor overheats on a primary sorter, the entire facility grinds to a halt. For logistics providers in India, where e-commerce demands and “same-day delivery” cycles are shrinking, even an hour of MHE (Material Handling Equipment) downtime can result in thousands of missed shipments and a massive spike in operational costs.
The challenge with warehouse automation is that it is often “out of sight, out of mind” until a catastrophic failure occurs. Traditional maintenance involves manual inspections that are prone to human error. A technician might miss a slightly misaligned belt or an unusually warm gearbox during a routine walk-through. This is where moving to a preventive maintenance CMMS changes the game.
By shifting from reactive “fix-it-when-it-breaks” repairs to a smart asset management strategy, logistics managers can track real-time metrics like Mean Time Between Failures (MTBF) and Overall Equipment Effectiveness (OEE). Integrating RTLS sensors directly into your conveyor line allows the system to detect vibration patterns or temperature spikes before a part actually fails. This ensures that maintenance happens during off-peak hours, keeping your throughput consistent and your delivery promises intact.
Overall, RTLS solutions and Digital twins can be a game-changer for businesses seeking to improve operational efficiency, reduce costs, and gain a competitive edge. By providing real-time visibility and actionable data, RTLS empowers businesses to make data-driven decisions and optimise their logistics yard operations for success through Yard Management System (YMS) integration, Bluetooth Low Energy (BLE) asset tags, and real-time trailer tracking & Shunter truck optimisation.
Warehouse Digital Twin: Visualise your yard operations in 3D for better space planning.
Smart CMMS Software: Automate maintenance for your shunter trucks and yard equipment.
Workplace Safety RTLS: Protect lone workers in expansive logistics yards.