High-quality real-time data is the foundation of automated, AI-driven processes in warehousing. Handheld scanners simply can’t deliver: their error rates are too high. To bring AI into intralogistics, the manual scanner must be replaced with cutting-edge solutions. Laser localization and real-time tracking allow Artificial Intelligence to take charge.
Data is the currency of future technologies. Artificial Intelligence (AI) can only optimize warehouse processes when supplied with high-quality, real-time data. Since the first Wrigley’s chewing gum was scanned in a U.S. supermarket in 1954, scanners have been central to capturing data. Barcodes have found their way into intralogistics. They are still an essential part of data collection. “New scanning innovations such as wearables, scan gates, and imagers are still celebrated by the industry, despite being rooted in decades-old technology,” says Martin Welp, Managing Partner at IdentPro, reflecting on this year’s industry events. However, the idea that the future is largely “scan-free” has yet to gain widespread acceptance. Real-time laser localization integrates goods information with geo-positioning, automatically capturing goods movements via sensors mounted on material handling equipment. This promises solutions to pressing warehouse bottlenecks and lays the groundwork for automated data processing in line with lean management principles.
AI Can’t Function on Error-Prone, Manually Collected Data
Efficient material flows are tightly synchronized. The journey from production machinery to shipping involves complex pathways. The top priority is seamless processes in intralogistics that, from a business perspective, must operate like clockwork: search and empty runs must be avoided, shortages eliminated, and inefficiencies reduced. Errors such as misplaced pallets and faulty scanned barcodes are bottlenecks in warehouses reliant on scanning technology for capturing data. Different storage types—such as racking, block storage, or high-bay warehouses—must be managed, often under significant space constraints. Adding to the challenge is a growing labor shortage, which is projected to worsen in the coming years. “Today, temporary workers and less-qualified staff often operate forklifts equipped with handheld scanners, taking on the critical task of data collection,” notes Martin Welp. While handheld scanners offer advantages such as low upfront investment, intuitive usability, and quick integration with existing software solutions, their long-term inefficiencies and high error rates can result in significant costs. AI, dependent on accurate data, cannot automate processes based on flawed, manually collected inputs.
Tracking Warehouse Movements “Scan-Free”: Connecting Goods IDs with Geo-Data
“The main reason many warehouse operators continue to rely on scanners is that meaningful and urgently needed alternatives haven’t fully penetrated the market,” explains Martin Welp. Yet promising developments in line with lean management principles suggest a largely scan-free, automated future for warehousing. Instead of manually capturing every movement within the warehouse, real-time laser localization (RTLS) enables automated, scanner-free tracking of material flows—whether handled by human-driven forklifts or autonomous mobile robots (AMRs).
Sensors mounted on forklifts, including load and height sensors alongside 2D LiDAR positioning sensors, provide precise location tracking of vehicles and objects within a defined space. This technology automatically detects and records the pickup and drop-off of load units, such as pallets, saving their positions in real time. The software links the load unit ID with its 3D coordinates in a digital twin. These goods are then automatically identified during every movement in the warehouse via a database query—no scanning required. Laser localization seamlessly integrates ERP and Warehouse Management Systems with real-world warehouse activities, creating a virtual representation that is accurate to the second and centimeter.
Advantages of laser localization in intralogistics:
Easy Transition to Laser Localization for More Efficient Warehouse Processes
In a warehouse equipped with a laser localization system, manual errors such as incorrect assignments or inventory loss are significantly reduced. The precise localization of vehicles and goods provides real-time visibility into all warehouse processes. Automated workflows and optimized traffic management eliminate search times and reduce empty runs, boosting warehouse productivity. More efficient resource utilization and reduced product damage result in cost savings and contribute to sustainable warehouse operations. “Our customers typically achieve a return on investment (ROI) within one to two years,” explains Martin Welp.
The use of IdentPro’s Warehouse Execution System (WES) is particularly worthwhile in industrial warehouses with 24/7 operations and multi-shift systems. The system also manages traffic safely and, unlike handheld scanners, knows the exact path to the target position thanks to its 3D forklift guidance system. “For many, our solution is a novelty. The industry has relied on individual item tracking via scanning for 50 years. We’ve only been in the market for six years,” adds Martin Welp.
Contrary to common concerns, switching to laser localization is quick and intuitive. Implementation requires project management and the installation of sensors on material handling equipment. Typically, warehouse infrastructure remains unchanged, requiring no additional hardware. The technology integrates seamlessly with existing ERP systems (e.g., SAP EWM). Once connected to the software, real-time tracking via laser localization can begin immediately.
Pilsner Urquell jumps a milestone in warehouse digitalisation with IdentPro
At Pilsner Urquell, the focus is not only on the quality of their beer but also on continuously improving processes. “Before partnering with IdentPro, we struggled to manage our inventory efficiently. Manual scanning was time-consuming, reducing both productivity and the accuracy of our warehouse data,” explains Tomáš Sedláček, Head of Logistics. The process was not only cumbersome but also negatively impacted warehouse safety. The lack of real-time visibility led to decisions based on static data, causing delays in warehouse operations. With the implementation of IdentPro’s Warehouse Execution System (WES), real-time localization now allows for second-by-second tracking of the entire inventory.
The AI-based software creates a digital twin of the warehouse, enabling intelligent control of transport tasks. “The introduction of the WES has brought immediate and significant improvements to the handling of empty containers, and most importantly, we’ve completely eliminated scanning,” Sedláček explains. “We are confident that IdentPro’s RTLS can further support our digitalization roadmap by allowing us to skip an evolutionary step where scanning would have been necessary.”
AI’s Work Begins Where Manually Collected Data Reaches Its Limits
The future of the logistics sector is undoubtedly characterized by challenging conditions: There are economic constraints, geopolitical tensions are delaying the global flow of goods and demographic developments are increasing the shortage of qualified personnel. Martin Welp sees this period of stagnation as the perfect time to invest in future-proof technologies and leaner processes: “Challenges don’t disappear by burying your head in the sand. By investing in digitalization, companies can tackle these challenges head-on and secure their long-term viability.”
To address intralogistics challenges with AI-driven, automated warehouse processes, companies must be prepared to fuel the technology with the currency of the future: high-quality, real-time data. While scanners, introduced decades ago, will continue to play a role at critical points in the warehouse, AI’s true potential begins where manually collected data falls short. Real-time laser localization lays the foundation for advanced warehouse applications and future readiness.