Initial Situation
Goals and challenges
ABF's Solution: 3D Forklift Guidance System with RTLS and SAP WM Integration
In the iFOS (intelligent Forklift Operation System) project, Bosch relied on ABF’s Forklift Guidance System innovation from the OneBase®MFT Intralogistics Suite. The 3D guidance system enables automatic tracking and booking of Euro pallets in the high-bay warehouse for both counterbalanced and reach trucks, thus forming the basis for end-to-end warehouse transparency.
To enable automated tracking of transports by manned forklifts, the forklift fleet was equipped with innovative technology. This included engineering, delivery, and commissioning of hardware for a laser-based Real-Time Locating System (RTLS), as well as laser height sensors and ultrasonic sensors for automatic load detection on seven forklifts. Additionally, industrial-grade DLoG forklift terminals were integrated to provide orders and information directly in the vehicle.
A crucial success factor was the standardized web service interface to SAP WM, which enables automated transport order creation and feedback (WM TORD), thereby supporting bookings without manual interactions. The system was complemented by a 3D visualization and a central 3D MFT Administrator application, making planning, control, and transparency centrally available in the warehouse. Goods receipt is handled by ground personnel using a standardized PDA app, including on Skorpio X3 barcode scanners, which supports defined processes for incoming goods.
Project Implementation
Result and Benefits
The increase in efficiency led to higher throughput in the warehouse and a significant reduction in the transport vehicle fleet.
At the same time, the solution enables significantly higher operational transparency because material movements can be automatically tracked and bookings can be made directly in SAP WM. Automatic tracking and SAP integration eliminate the need for time-consuming barcode scans and simplify continuous inventory management, which offers tangible advantages, especially in large high-bay warehouses with many storage locations. Furthermore, Bosch reports optimized resource utilization, reduced energy consumption, and lower accident risk, all while maintaining full transparency ‘from the desk’.
