Warehouse Execution System
FAQ: Answers to Your Questions About Digital Intralogistics
When moving toward real-time warehouse digitalization, many practical questions arise:
How does a Warehouse Execution System (WES) work in daily operations? What are the benefits of a Digital Twin? And how does it integrate with systems such as SAP?
In this FAQ, we have compiled the most common questions regarding the introduction, integration, and use of our Warehouse Execution System. Here you will learn how we connect forklifts – both manual and autonomous – into one collaborative fleet, what technology powers this, and how companies use it to make their warehouse operations measurably more efficient. Whether you are interested in technical aspects, integration options, or ROI, these answers explain what our solution delivers in real warehouse environments.
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General Informationen
Companies with complex internal material flows benefit the most from a WES. Especially industrial companies with their own warehouses and multiple manned forklifts, regardless of size (mid-size to global enterprise).
A WES delivers the greatest value where material movements are frequent, dynamic, and cross-site wherever transparency, efficiency, and real-time data are essential for reducing costs and ensuring stable processes.
The WES increases efficiency across all industries without product-specific limitations. It is especially valuable where material flows are complex, time-critical, and interconnected.
Examples of industries already using the WES:
- Beverage industry: Empty-container handling, production supply, outbound logistics.
- Food industry: Secure and traceable flows at high throughput and hygiene standards.
- Paper & packaging: Real-time traceability for bales, rolls, and finished goods.
- Building materials & chemicals: Precise tracking of heavy or bulky goods indoors/outdoors.
- Furniture & wood: Mixed fleets, high turnover volumes, efficient replenishment.
- Steel & metal: Full transparency from mid-size to corporate environments.
WES is worthwhile wherever material flows need to be controlled precisely, transparently, and flexibly. This applies regardless of whether the focus is on production or shipping.
The WES supports continuous 24/7 operations and all shift models: from single-shift to three-shift or more.
Key capabilities:
- Automatic handover between shifts (tasks, vehicle positions, inventory)
- No control room staff required per shift: autonomous operation possible
- Role-based user login for drivers at the forklift terminal regardless of shift time
This makes WES ideal for companies that produce, store, or ship goods around the clock, or for businesses that want to flexibly combine different shift models.
Yes, WES can be used both indoors and outdoors. Thanks to LiDAR and IoT-based positioning technology, forklift trucks can also be precisely located outdoors, without the need for GPS. This allows the entire material flow to be seamlessly mapped across hall boundaries.
Use cases:
- Indoor high-bay, block storage, pallet racking
- Outdoor yards and raw-material or finished-goods areas
- Mixed indoor–outdoor transitions (e.g., docks/ramps)
The system is designed to automatically detect changes between indoor and outdoor zones and process them without interruption. This creates a continuous digital twin of the entire factory premises, from the production warehouse to the shipping area.
The WES is designed to be independent of storage and shelving systems. It can be used in almost any warehouse environment, regardless of whether it is an existing warehouse or a new construction project.
Supported storage and shelving types in indoor and outdoor areas include, among others:
- Block storage and open storage
- Rack storage, e.g., high-bay, pallet, or flow racks
- Production-related buffer and staging areas
- Random or fixed storage location systems
- Special storage areas such as empties, bales, or roll storage
Since WES is based on real-time location systems (RTLS), it does not require physical scanners or floor markings. This means that the system can even be used in unmapped or dynamically used storage areas.
The WES supports all common types of forklifts and forklift trucks, regardless of the manufacturer.
These include, among others:
- Front forklifts (electric, diesel, gas)
- Reach trucks and high-lift trucks
- Order pickers and narrow aisle trucks
- Side-sitting and four-way trucks
- Tugger trains and tow trains
- In collaborative use with driverless transport systems (DTS) such as autonomous mobile robots (AMR) or automated guided vehicles (AGV)
Each vehicle is stored in the system with an individual vehicle profile (including load capacity, lift height, attachments, indoor/outdoor approval, and area of application). This enables the WES to jointly control and optimize mixed fleets of manual, semi-automated, and autonomous vehicles. This is a decisive advantage over classic forklift guidance systems.
Yes, different types of forklifts can be fully represented and managed in WES. Each forklift type is assigned its own vehicle profile with all relevant parameters, e.g.:
- Load capacity, lift height, and design
- Attachments (e.g., rotator, clamp, double pallet fork)
- Indoor/outdoor approval
- Speed, safety zones, and areas of application
The project duration until go-live depends on the size of the warehouse, the number of vehicles, the integration requirements (e.g., SAP connection), and the desired functional coverage. However, based on experience, a clear framework can be provided:
Typical project schedule:
- Analysis & concept phase: 2–6 weeks
Identification of processes, definition of interfaces, coordination of target architecture
- Implementation & retrofit phase: 6–12 weeks
Retrofitting of vehicles with LiDAR/IoT, software setup, test environment
- Pilot operation & go-live: 2–4 weeks
Real-time operation in selected storage areas, fine-tuning of rules
- Stabilization & hypercare phase: 4–8 weeks
Accompanied optimization until fully stable continuous operation
Total time:
Depending on the scope, it takes between 3 and 6 months from project start to stable, productive operation. Thanks to standardized interfaces and modular architecture, faster rollouts are also possible.
The WES does not require any structural modifications to the warehouse infrastructure. All that is needed is a solid IT and power supply. This makes it ideal for existing warehouses and established locations where innovation needs to be implemented quickly and without altering the building structure.
System Features
Yes, WES includes a powerful SLS. It uses AI-based software algorithms that calculate the best possible distribution of all transport orders generated by a warehouse management system to the vehicle fleet at any given time. The result is, among other things, a forklift guidance system that significantly reduces empty runs while maintaining order priorities.
WES enables precise real-time localization of all forklift trucks and goods in the warehouse – both indoors and outdoors. The position of the vehicles is determined using a LiDAR-SLAM solution developed by IdentPro. This vehicle-based localization technology operates in real time (RTLS) and works without any additional infrastructure such as reflectors, markers, or GPS.
The final 3D localization of the loads is then determined using additional IoT-based distance sensors on the forklift tools. Typical performance features:
- Centimeter-precise positioning of every forklift and goods in real time
- Continuous updating of vehicle movements in the digital twin
- Automatic detection of locations, parking spaces, and transfer zones
- Suitable for indoor and outdoor use, even across hall boundaries
Each vehicle is equipped with a retrofit kit consisting of a LiDAR sensor, onboard computer, and transmitter module. These components capture the surrounding environment, compare it with the digital warehouse map, and continuously transmit position data to the WES. This means that the system knows the exact position and status of each vehicle at all times, providing the basis for efficient order distribution, route optimization, and complete transparency in the material flow.
The WES features intelligent dual-cycle logic that specifically reduces empty runs and increases the efficiency of the entire fleet. The system combines transport orders so that vehicles perform useful tasks on both the outward and return journeys, for example by storing one pallet and removing another at the same time.
Typical application scenarios:
- Storage and retrieval in a combined delivery order
- Return transport of empties after goods delivery
- Order linking between adjacent storage zones
- Use of empty runs for relocation or supply
The WES continuously evaluates all open orders and checks whether trips can be linked to form logical double cycles. It takes into account factors such as direction of travel, distance, priority, and vehicle type.
The WES creates a digital twin of the entire warehouse, including buildings, storage zones, shelves, storage locations, vehicles, and inventory. The digital twin is automatically generated from real-time data from networked forklift trucks and sensors. This creates a virtual representation of all physical processes in the warehouse, accurate to the second, without the need for manual data entry.
Typical contents of the digital twin:
- Building structure and storage areas (e.g., block storage, high-bay storage, outdoor storage)
- Vehicle positions and movements in real time
- Inventory and storage location information down to the pallet level
- Material flows and order status across all process steps
The retrofitted vehicles in the warehouse use LiDAR and IoT technology to scan their surroundings and continuously synchronize the data collected with the central system. This allows all goods movements in the WES to be tracked with second- and centimeter-level accuracy. The digital twin gives companies full transparency over their material flow – in real time and without manual scans or additional infrastructure.
Yes, different types of load carriers can be fully represented and individually managed in WES. This allows the entire material flow to be displayed realistically and accurately in the digital twin.
Typical load carrier types:
- Euro pallets, industrial pallets, and disposable pallets
- Pallet cages and special load carriers
- Roll containers and big bags
- Bales, rolls, or barrels
- Empty containers and reusable containers
Each load carrier type is stored in the system with its own attributes and movement rules (e.g., dimensions, weight, stackability, or assignment to specific storage zones). The WES recognizes which load carrier has been transported or parked and tracks its position in real time in the digital twin. These are displayed in simplified form on the map.
Yes, WES enables comprehensive historical analysis of all material flows in the warehouse. All movements, positions and order data are permanently logged in the system and are available for evaluation.
Typical analysis options:
- Tracking of individual goods movements down to pallet or order level
- Time-based evaluations of throughput times, transport routes and process durations
- Comparison of target and actual processes for continuous process improvement
- Visualisation of historical movements in the digital twin
Every transport and storage action is automatically stored in the WES with a time stamp, vehicle ID and location data. This information can be evaluated via dashboards or reports and filtered according to any criteria. IdentPro WES thus provides a complete, audit-proof history of all material flows: the basis for transparency, process optimisation and quality assurance.
The WES is multilingual and can be flexibly adapted to the respective national language or user group.
Languages available as standard: German / English
Expandable on request: Additional languages can be integrated as required, for example for internationally active customers or multilingual teams.
Thanks to the modular system architecture, the user interface and message texts can be easily translated without having to adapt the software core. IdentPro WES speaks the language of your users, whether in Germany, Europe, or worldwide.
Yes, WES has a comprehensive range of fleet management functions that transparently control and optimize all forklift and vehicle operations. Both manual forklift trucks and autonomous vehicles (AMR, AGV, etc.) can be integrated into a central system.
Yes, WES can work with external fleet management systems. The solution is deliberately designed to be open and integrative so that existing systems can continue to be used and integrated, especially in mixed fleets or step-by-step modernization strategies.
Yes, the WES can be seamlessly connected to all common ERP, WMS, and MES systems, including SAP ECC and SAP S/4HANA (including EWM).
Technical integration:
- Standardized interfaces: REST API, IDoc, OData, or OPC UA
- Event-driven data exchange in real time: e.g., for goods receipt, stock transfer, production replenishment, or shipping
- Bidirectional communication: The WES receives orders from an ERP system/WMS and reports back status, inventory changes, or acknowledgments
Examples of integrated processes:
- Goods receipt and goods dispatch bookings
- Production supply and replenishment control
- Transport and stock transfer orders
- Shipping preparation and loading processes
Integration is achieved using proven standard interfaces, without the need for extensive modifications to the existing IT landscape. This allows the WES to be quickly implemented in existing environments and expanded later if necessary. Whether SAP, Infor, Navision, Microsoft Dynamics, or another WMS: the WES integrates seamlessly into your system environment and ensures a consistent flow of information.
Yes, WES can capture goods movements directly in the connected ERP or WMS system. The system works bidirectionally: it receives transport or warehouse orders from the ERP/WMS, controls their execution in the warehouse in real time, and then automatically reports the results back.
Typical booking processes:
- Goods receipt & storage
- Stock transfers & replenishment orders
- Production supply & finished goods transport
- Order picking & dispatch preparation
- Status notifications
Each work step is recorded by WES in real time and automatically confirmed in the ERP/WMS without manual scans or entries. All postings are made via standardized interfaces (e.g., SAP IDoc, OData, REST), ensuring that processes are documented securely and in an audit-proof manner.
Order Distribution
The WES automatically and intelligently distributes transport orders to the available forklift trucks based on real-time data from the warehouse and individually configurable rules.
Typical decision factors for order distribution:
- Position of the vehicle in the warehouse (nearest available forklift)
- Vehicle type and equipment (e.g., load capacity, lift height, attachments)
- Order priority and urgency
- Current utilization of vehicles
- Restricted areas, traffic flow, or blockages
The system continuously evaluates all open orders and calculates the optimal assignment for each vehicle. Based on this, orders are automatically assigned to the most suitable vehicle.
Yes, WES allows you to assign different priorities to transport orders. This means that time-critical or particularly important tasks can be given preferential treatment, regardless of when they were created in the system.
Typical prioritization criteria:
- Order type (e.g., production supply before stock transfer)
- Due date or time window
- Related production orders or sales orders
- Storage area or process stage
- Urgency status (high, medium, low)
The WES evaluates all open orders according to their priority characteristics and automatically assigns a dynamic ranking. This priority is directly incorporated into order distribution and route optimization, so that urgent transports are given priority.
The WES does not offer automatic storage location suggestion and allocation logic. This is transmitted from the ERP/WMS to the WES or carried out by the drivers. Typical criteria for storage location selection:
- Item and core data (dimensions, weight, hazardous goods class, etc.)
- Storage strategy (e.g., FIFO, FEFO, ABC, chaotic, or fixed location-based)
- Zone affiliation (temperature range, proximity to production, external warehouse, etc.)
- Route optimization – shortest distance between source and destination
- Available capacity and current occupancy
However, each time goods are stored, the WES automatically checks whether other items with predefined characteristics are already present in the warehouse. This enables drivers to store goods by type as far as possible if there is no target location control. This is particularly relevant in block and external warehouses.
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