KINEXON Solutions

Forklift Fleet Execution

Track and guide manually operated forklifts integrated into your intralogistics processes and systems to lower costs and boost throughput​

For decades, your forklift fleet has kept operations moving. Why digitize now?​

Forklifts remain essential to shop floor logistics because they are flexible, available, and hard to fully replace in dynamic industrial environments. Yet they remain one of the last blind spots in industrial automation by impacting efficiency and commercial performance. ​

Low Utilization
Average forklift fleet utilization around 35% indicates huge potential for fleet-size reduction to save operating costs
Unnecessary Runs​
66% of total travel distance are empty-fork runs revealing the need route optimizations to eliminate non-value-adding motion.​
Manual Search​
20% of total order-pick time are spent on manual search for loads, pallets and pick up locations, a waste of costly labor time.​
Poor Dispatching​
Manual, inaccurate or non-optimized task assignments cause urgent tasks being delayed and workloads becoming uneven.​
Limited Transparency​
Untapped cycle time reduction potential of ~30% pinpoints the need for real-time localization and visualization of forklifts.​
Low Utilization
Average forklift fleet utilization around 35% indicates huge potential for fleet-size reduction to save operating costs
Unnecessary Runs​
66% of total travel distance are empty-fork runs revealing the need route optimizations to eliminate non-value-adding motion.​
Manual Search​
20% of total order-pick time are spent on manual search for loads, pallets and pick up locations, a waste of costly labor time.​
Poor Dispatching​
Manual, inaccurate or non-optimized task assignments cause urgent tasks being delayed and workloads becoming uneven.​
Limited Transparency​
Untapped cycle time reduction potential of ~30% pinpoints the need for real-time localization and visualization of forklifts.​
KINEXON Fleet Manager supports many AGVs and AMRs types and manufactures

Forklift Fleet Execution Brings Real-Time Visibility, Control, and Orchestration to Your Forklift Operations​

Forklift Tracking Creates Real-Time Visibility​

Retrofit your forklift fleet with vSLAM technology to track movements with the highest precision. Our platform creates a digital shop floor twin, enabling you to gain full transparency across your entire fleet, visualize transport routes, and receive real-time alerts. KINEXON helps you identify critical paths, detect idle runs, and analyze search times to drive continuous optimization.

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<1 week to your first tracked forklift, from installation to live operations
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100% transport visibility across active forklift movements trough real-time tracking
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Capture historic movements as basis for data-driven optimization
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Reduce inefficient search times for available forklifts, palettes, or production orders
Explore forklift tracking with KINEXON OS

Forklift Guidance Connects Operators with Shop Floor Systems​

Connect your forklifts directly to your existing business and production systems. Every transport order goes to the right operator, at the right time, without a single manual dispatch. Our platform assigns jobs based on proximity and priority, cutting idle runs and keeping material flowing. Operators stay in control through a mobile interface that shows what to move, where, when and confirms completion automatically.

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Up to 20% more out of every forklift — just by dispatching and routing them smarter
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Minimize idle runs and maximize throughput across your entire forklift fleet
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One agnostic platform connects forklifts from any vendor, fully integrated with your WMS, MES, and existing systems
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Transport orders visualized on forklift tablets guide operators from pick up till drop off locations​
Guide your forklifts with KINEXON Fleet Manager

Hybrid Fleet Orchestration Unifies Forklifts and Mobile Robots Fleets​

Fully automate traffic management including critical routes, busy intersections, connected gates, manual workzones, and shared paths with mobile robots, tugger trains, or human workforce. Our platform statistics support you in maximizing fleet utilization and optimizing transport routes to pave the way for autonomous mobile robots atscale.

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Full-fleet ROI in under six months — one of the fastest paybacks in industrial automation
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Prevent up to 80% of near-miss events with dynamic AMR safety zones that adapt in real time
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Maximize fleet utilization that directly cuts operating costs across every shift
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Live shopfloor updates that give every team member a single, accurate operational picture
Orchestrate with KINEXON Fleet Manager

Ready to Digitize Your Forklift Fleet? Start in 3 Steps and Achieve ROI in Less Than 6 Months

Forklift operating within a defined warehouse zone, with location tracking and status data transmitted to a central system for real-time monitoring.
Step 1

Retrofit Your Forklift Fleet

vSLAM technology enables precise, infrastructure-free localization without replacing vehicles or installing additional hardware. Gain real-time visibility into every transport, optimize fleet utilization, and lay the foundation for automated material handling and Physical AI. Make sure you have:

Forklifts transport pallets between storage locations while exchanging inventory and location data with a warehouse management system (WMS).
Step 2

Digitize and Connect Your Forklift Fleet

Transform conventional forklifts into connected, intelligent assets. KINEXON OS delivers real-time visibility into every vehicle, optimizes transport execution, and seamlessly integrates manual forklifts with automated workflows and mobile robot fleets. Your benefits:

Tracked forklift and autonomous mobile robot (AMR) coordinate material movement, with the system detecting locations and issuing alerts to prevent routing conflicts.
Step 3

Execute Your Forklift Fleet at Scale

Fully automate traffic management including critical routes, busy intersections, connected gates, manual work zones, and shared paths with mobile robots, tugger trains, or human workforce. Maximize your fleet utilization, optimize transport routes and pave the way for autonomous mobile robots at scale.

From Blind Spot to Bottom Line: How Digitalizing Manual Forklifts Drives Commercial Gains

<1 Week to Go Live
Accelerate time to value with easy installation, software deployment in less than a week, and payback in under six months—all backed by proven industrial expertise across SMEs, MROs, and OEMs.
95% Automated Bookings​
Digitize manual dispatching tasks same as manual confirmations for order pick up, drop off, or transport status updates – all in real-time synchronization thanks to certified SAP integrations.​
30% Utilization Increase​
Depending on the maturity level of your intralogistics automation, route optimization and intelligent dispatching can result in 30% smaller fleets, around 40% less travel distance, about 30% faster cycle times.​
25+ Integrated Manufacturers​
Vendor-agnostic by design, our platform integrates forklifts tracked with vSLAM or UWB alongside with VDA5050 mobile robots of more than 25 leading vendors out of the box.​
1 Automation Platform​
Choosing KINEXON for forklift tracking sets the foundation for all-in-one intralogistics automation with mobile robot fleet management and material flow orchestration.​
65,000+ Tracked Assets
​… and 4,000+ daily users live in production across 14 plants worldwide at BMW proof industrial-grade scalability, stability and data security.​

Explore Powerful KINEXON Products for Autonomous Material Flow

Real-time automation platform connecting shopfloor movements with enterprise systems. Built to integrate any location tracking technology >
Vendor-independent fleet orchestration for mobile robots and forklifts. Built to unify mixed fleets, seamlessly connected to business systems >

Frequently Asked Questions

Explore the most common questions about forklift fleet execution and guidance.

What is forklift fleet execution?

Forklift fleet execution connects real-time fleet management with transport execution. It continuously monitors vehicle positions, assigns transport orders, optimizes routes, and orchestrates material movements across your operation—all in real time, all in one platform.

How is forklift fleet execution different from traditional forklift fleet management?

Traditional forklift fleet management provides visibility into vehicle locations, utilization, and status. Forklift fleet execution builds on this foundation by dynamically assigning transport tasks, coordinating vehicles, and optimizing material flow based on live operational data.

How does forklift fleet execution improve intralogistics?

By combining real-time location data, integrated into KINEXON OS, with transport orders and production priorities, forklift fleet execution reduces empty runs, shortens transport times, minimizes manual coordination, and ensures the right material reaches the right place at the right time.

Can forklift fleet execution integrate with my existing systems and fleets?

Yes. KINEXON integrates with ERP, MES, WMS, and shop floor systems while supporting mixed fleets of forklifts, AGVs, and AMRs from any vendor. The KINEXON Fleet Manager allows you to optimize existing operations without vendor lock-in.

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