In-Plant TAT Optimization and Traffic Management of Truck or Train Fleet


Warehousing & Logistics, FMCG, Steel, Automotive, Automotive Components, Electronics, Electronics Components, Electrical, White Goods & White Goods Components, Aerospace and Defense


Digital Supply Chain, Industry 4.0, Smart Logistics, Truck Tracking, Train Tracking, Forklift, Transport Management System, TAT Optimization, Traffic Management, Safety Monitoring


Plants, warehouses and even mines have a large fleet of trucks or trains entering their premises on a daily basis. Truck movement into and within the plant area is often asynchronized with loading and dispatch schedules, trucks take too much time within the plant premises between entry and exit, and there are either bottlenecks or a lot of idle time at various points. This results in loading bay underutilization, dispatch inefficiency and missed delivery schedules.
Organizations with a manual verification, scheduling and sequencing process often face high loading and unloading delays, congested roads and fire-fighting with transporters or railways. Lack of visibility of the fleet movement inside the premises restricts their ability to control and manage the flow inside premises or identify and address gaps in the process.

  • No data to identify delays in internal TAT for loading or unloading material
  • High TAT results in increased logistics detention costs or unfavorable commercial terms by transporters
  • Lack of movement visibility restricts the organization’s ability to enforce safety compliance standards
  • No data driven means to manage the internal traffic and clear chokepoints
  • High TAT results in inventory pile-ups thereby increasing inventory holding costs and decreasing space utilization

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Solution Approach
  • Virtual set-up of stages or location monitoring zones throughout the premises (gate, parking, loading or unloading bay, weighment area, waiting area etc.) on a web-portal
  • A battery-operated Kreto sensor tag to be attached to the truck or locomotive when it enters the plant and removed when it exits the plant
  • Sensor tag can capture and relay information such as current location, time-in and time-out stamps at different locations and motion status
  • A web portal to map the tag to the truck or locomotive and add shipment information
  • Integration with ERP or TMS to auto-update trip indent, shipment information and ePODs
  • Traffic lights with sirens installed at blind spots trigger visual and sound warning alarms when the truck or locomotive is about to arrive
  • Live location tracking of truck or locomotive fleet inside the premises on a web-dashboard for real time traffic monitoring and guidance
  • Reports with segmented TAT along with idle-time and run-time for every stage of the truck or locomotive fleet inside the premises
  • Automated real time deviation alerts along with open tickets to relevant stakeholders if the system observes the following deviations
    • Abnormally high TAT beyond a configured baseline at specific location zones (dispatch bay, parking area, weighment area etc.)
    • Route deviation from pre-configured shortest routes
    • Any unnecessary halt or restricted area entry breach
  • Shift performance analytics on a web dashboard with KPIs such as number of trips, average TAT and number of deviations
  • Deviation management web-based system with all open tickets and deviation information to investigate the root-cause of the deviation for continuous process improvementd
  • Pareto analysis reports with high TAT root-causes to identify low performing:
    • Drivers
    • Location-zones (loading/unloading bays, parking area etc.) inside the plant
    • Transporters
    • Customer shipment type
  • Heat-map and Spaghetti diagram analysis to visualize the flow, traffic density and bottlenecks at different times

  • Prevention of collisions and accidents due to traffic blind spots
  • Lowering of TAT by identifying bottlenecks through data driven insights
  • Reduction in logistics detention costs and favorable commercial terms by transporters
  • Reduction in lost shipping days and dispatch delays
  • Decrease in inventory pile-ups and associated inventory holding costs
  • Increase in process throughput by up to 20% by digital process validation, minimizing stop times and increase in number of cycle trips
  • Improved space utilization with underutilized space optimization through heat-map and spaghetti analysis
  • Higher system uptime and reliability than a typical RFID, GPS or BLE Beacon based solution