Case Study
ABB × Signalo
Intralogistics optimization, cost reduction, and full control over material flow with the ForkFleet system.
Challenge
Cost reduction • Better organization • Process visibility
→ Forklifts were everywhere — yet when they were truly needed, finding an available vehicle and a qualified operator was difficult.
→ The result? Time wasted searching for equipment, production delays, and a growing sense of frustration. The challenge was to make the entire fleet and operator team work as a coordinated system instead of disconnected elements.
Transformation
A partnership with SIGNALO focused on implementing the ForkFleet system.
Before implementation, ABB’s factory required a large number of forklift operators.
The new system automated many processes, significantly reducing the labor hours needed for forklift operations and generating substantial cost savings.
The system enables precise monitoring of material and product movement across the plant.
This allows route optimization and reduced travel times.
Faster fulfillment translates directly into higher customer satisfaction and competitiveness.
The forklift management system collects critical operational data.
Advanced analytics enable more informed decisions.
Data analysis helps identify optimization areas and eliminate waste, supporting ABB’s long-term strategy.
Process optimization and automation allowed ABB to significantly reduce the number of forklifts required.
This lowered purchase, maintenance, and service costs while improving workplace safety and organization.
The system enables precise planning of internal routes and operations.
This improves control over intralogistics processes and prevents delivery delays and errors.
Results
IT systems for manufacturing delivered real results:
- Reduced task assignment times
- Reduced service call times
- Shorter operation execution times
- Improved process analysis
Growth in the following areas:
- Productivity
- Situational awareness
- Resource utilization
→ The ForkFleet implementation at ABB’s Bielsko-Biała plant proved to be a breakthrough — delivering higher operational efficiency and tangible cost savings.
→ Fewer required operators and forklifts, shorter order fulfillment times, full control over material flow, and data-driven decisions all contributed to improved competitiveness and profitability.
→ This is just one example of how our solutions bring real innovation to intralogistics and deliver measurable impact.
→ We have delivered many such implementations. Now it’s time for your plant. Reduce costs and increase efficiency.
Do you see similar challenges in your intralogistics?
- Forklifts are constantly moving, yet it’s hard to find an available one exactly when it’s needed.
- Operators waste time searching for equipment or tasks instead of doing productive work.
- Material flow is unpredictable, leading to downtime and a tense working environment.
- There is a lack of data to support decision-making and eliminate waste.
How do we help plants in this situation?
Fleet organization and automation
ForkFleet removes chaos — each forklift has clear tasks assigned, and operators work where they are truly needed.
Better resource utilization
Route and operator optimization shortens execution times and reduces the need for excess equipment.
Data-driven decisions
The system delivers clear operational insights, allowing management to see real workloads and eliminate losses.
See what this kind of change could look like in your plant
The analysis takes 30 minutes. You don’t need to prepare anything — we handle everything for you.
Book a free consultation