RTLS & Digital Twins for
AGV Fleet Management

Not all deliveries are equal. Prioritize what matters most.

What We Capture

• Real-time production line consumption rates and buffer levels from MES.
• Material criticality scores based on line stoppage risk.
• Current AGV positions, loads, and estimated delivery times.
• Alternative routing options and traffic conditions.

What It Enables

• Automatic priority routing for AGVs carrying critical materials.
• Preferred intersection crossing for high-priority deliveries.
• Temporary traffic slowdown of non-critical vehicles when needed.
• Predictive alerts when critical deliveries are at risk of delay.

Operational Outcomes

• 60–75% reduction in production line stoppages due to material shortages.
• 35–45% improvement in on-time delivery for critical materials.
• $1.8M–$3.2M annual savings from prevented downtime.

Know where critical WIP is and route around congestion.

What We Capture

• Real-time WIP location tracking through RTLS tags on containers/pallets.
• Production zone congestion levels and bottleneck identification.
• Material flow patterns and staging area utilization.
• Historical traffic data around production areas.

What It Enables

• Automatic routing around congested production zones.
• Identification of WIP staging bottlenecks before they impact flow.
• Optimized material placement based on production consumption patterns.
• Predictive alerts when WIP is accumulating in wrong locations.

Operational Outcomes

• 25–35% reduction in material handling time through optimized routing.
• 40–50% decrease in WIP search time and misplaced materials.
• Improved production flow with fewer staging bottlenecks.

Route around production congestion automatically.

What We Capture

• Real-time production line status and throughput rates.
• Vehicle density and dwell time in production zones.
• Staging area congestion and material accumulation.
• Alternative routing options and travel time estimates.

What It Enables

• Automatic rerouting when production areas become congested.
• Predictive bottleneck detection before traffic accumulates.
• Load balancing across multiple delivery routes to same destination.
• Temporary zone restrictions during production changeovers.

Operational Outcomes

• 30–40% reduction in vehicle wait time at production zones.
• 20–30% improvement in overall fleet throughput.
• Fewer production disruptions from material handling congestion.

Enforce speed limits where and when they matter most.

What We Capture

• Real-time speed of all vehicles (manual and automated).
• Personnel locations and proximity to vehicle traffic.
• AGV positions and planned paths.
• Zone-specific speed limits and high-risk areas.

What It Enables

• Automatic speed limit alerts to manual vehicle operators when exceeding limits.
• Dynamic speed zones that activate when personnel are present.
• Reduced speed enforcement near AGV traffic and intersections.
• Supervisor alerts for repeated speed violations with operator identification.

Operational Outcomes

• 70–85% reduction in speed-related near-miss incidents.
• Verified speed compliance for safety audits and insurance.
• Improved operator behavior through real-time feedback.

Protect workers with dynamic safety zones that follow them.

What We Capture

• Real-time personnel location with wearable RTLS tags.
• Worker movement patterns and high-traffic pedestrian areas.
• All vehicle positions and velocities (AGV and manual).
• Zone-specific safety buffer requirements.

What It Enables

• Dynamic safety buffers that move with each worker.
• Automatic collision warnings to AGVs when workers are nearby.
• Speed limit alerts to manual operators approaching pedestrians.
• Temporary zone restrictions when workers enter high-risk areas.

Operational Outcomes

• 92–97% reduction in vehicle-pedestrian near-miss incidents.
• Complete incident documentation for safety investigations.
• Improved worker confidence and reduced safety anxiety.

Prevent collisions between any vehicle types.

What We Capture

• Position, velocity, and trajectory of all vehicles (AGV, forklift, tugger, etc.).
• Intersection crossing patterns and high-risk zones.
• Blind spot areas and limited visibility zones.
• Historical near-miss data and collision risk patterns.

What It Enables

• Predictive collision warnings 3–5 seconds before potential impact.
• AGV system integration for automatic slowdown or stop.
• In-cab alerts for manual vehicle operators with directional guidance.
• Intersection coordination warnings for crossing vehicles.

Operational Outcomes

• 88–94% reduction in vehicle-to-vehicle collision incidents.
• Prevented equipment damage and downtime costs.
• Complete incident documentation for insurance and safety audits.

Coordinate all vehicles, not just AGVs, for optimal traffic flow.

What We Capture

• Real-time positions of all vehicles (automated and manual).
• Intersection crossing patterns and wait times.
• Zone congestion levels and traffic density.
• Task priorities and delivery urgency.

What It Enables

• Coordinated intersection crossing for AGVs and manual vehicles.
• Priority-based traffic sequencing (critical loads first).
• Dynamic rerouting suggestions for manual operators.
• Congestion prediction and proactive traffic management.

Operational Outcomes

• 35–50% reduction in intersection wait times.
• 25–35% improvement in overall fleet throughput.
• Elimination of traffic gridlock during peak periods.

Optimize paths based on traffic, production, and priorities.

What We Capture

• Current traffic conditions and predicted congestion.
• Production zone status and bottleneck locations.
• Load criticality and delivery time requirements.
• Alternative routing options and travel time estimates.

What It Enables

• Context-aware routing that considers production priorities.
• Dynamic path recalculation when conditions change.
• Load balancing across multiple routes to same destination.
• Predictive routing that avoids forming bottlenecks.

Operational Outcomes

• 20–30% reduction in average travel time per task.
• 40–55% improvement in on-time delivery for critical loads.
• Consistent throughput even during peak operational periods.

Understand utilization across your entire mixed fleet.

LocaXion’s Fleet Utilization Analytics provides comprehensive visibility into how every vehicle—automated or manual—is performing, enabling smarter decisions for fleet optimization and automation ROI.

What We Capture

• Active time vs. idle time per vehicle (AGV and manual).
• Task completion rates and cycle times by vehicle type.
• Distance traveled (loaded vs. empty) across fleet.
• Operator performance metrics for manual vehicles.

What It Enables

• Identification of underutilized vehicles and peak demand periods.
• Comparative analysis between AGV and manual vehicle efficiency.
• Right-sizing recommendations for fleet composition.
• ROI analysis for automation expansion decisions.

Operational Outcomes

• 25–35% improvement in overall fleet utilization.
• Data-driven decisions on AGV vs. manual vehicle allocation.
• Quantified ROI for fleet expansion or automation investments.