Forklift Tracking for scanless inventory control

Introduction

ArcelorMittal, the world’s leading steel and mining company, faces unique challenges in its AMF (ArcelorMittal France) division, where customized metal coils, rings and sheet-bundles are produced for the food packaging industry. This division operates in a high-demand environment characterized by Just-In-Time (JIT) delivery principles and a diverse inventory of tailored products. Managing inventory efficiently while maintaining seamless operations has been a persistent challenge.

To address this, ArcelorMittal integrated the Pozyx Real-Time Location System (RTLS) into their operations, streamlining how they track and manage inventory in their warehouse.

Challenges

• Complex Inventory Management
  The warehouse stores a wide variety of sheet metal products tailored to specific customer requirements. Each product’s uniqueness adds complexity to storage and retrieval processes.
• Pressure of Just-In-Time Delivery
  Food packaging customers require JIT deliveries, demanding precise inventory control and rapid response times.
• Warehouse Layout and Scale
  The warehouse is a large open space with stacked sheet metal, making it difficult to visually track inventory and locate specific orders efficiently.
• Limited ERP Integration
  Without accurate, real-time data on the physical location of inventory within the warehouse, the existing ERP system was unable to provide the required level of operational visibility.

Solution: Implementing Pozyx RTLS

ArcelorMittal implemented the Pozyx Real-Time Location System by equipping forklifts with Pozyx UWB trackers. This technology enables precise tracking of forklift locations (up to 10cm) as they move inventory across the warehouse.

When inventory is dropped off, the system automatically registers its location, creating an indirect inventory tracking solution. Unlike traditional methods, this approach tracks only the forklifts—not the inventory itself—resulting in a cost-effective and streamlined process.

The forklift UWB trackers operate by emitting radio signals captured by fixed nodes called anchors. Once at least three anchors detect the signals, the system calculates the exact location of the tracker. For indirect inventory tracking, forklifts need to be tracked only in specific areas where goods are deposited. This targeted tracking minimizes the required infrastructure, as anchors are installed only in designated drop-off zones. The result is a cost-efficient, quick-to-deploy solution with reduced installation time and expense.

At ArcelorMittals site at Florange, France. A total of 86 anchors were used to cover a warehousing space of over 26.000 sqm.

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To integrate seamlessly with ArcelorMittal’s ERP system, which uses bin locations rather than x, y coordinates for inventory management, a mapping process was undertaken during project commissioning. Now, each time a customer order is dropped off, its location is automatically recorded using the Pozyx API’s and linked to the corresponding entry in the ERP system.

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Results

• Improved Inventory Accuracy
  The precise tracking provided by Pozyx eliminated discrepancies in inventory records, ensuring products are stored and retrieved with minimal errors.
• Increased Operational Efficiency
  Warehouse staff can quickly locate and retrieve products, reducing delays in JIT deliveries.
• Enhanced Customer Satisfaction
  Faster, more reliable deliveries strengthened ArcelorMittal’s reputation as a dependable supplier for automotive manufacturers.
• Streamlined Processes
  Real-time location data eliminated the need for manual tracking, freeing up resources and reducing operational costs.

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Conclusion

By leveraging Pozyx RTLS, ArcelorMittal France division transformed its inventory management processes, enabling precise control over its extensive, customized inventory. The solution not only enhanced operational efficiency but also strengthened the company’s ability to meet JIT delivery requirements, ensuring a competitive edge in the food packaging industry.

Ready to revolutionize your warehouse operations? Contact Pozyx today to learn how we can empower your business with real-time location solutions.

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