Warehouse Execution System
How can I reduce empty runs of my forklift trucks?
And why do so many warehouses operate more vehicles than they actually need?
Where do empty runs come from and why are they so hard to avoid?
Every forklift truck operator driving through the warehouse without a load consumes time, energy and capacity without generating any value. That much is well known. What is less well known: in most warehouses, a significant share of all trips is structurally avoidable — not because operators are working poorly, but because assignments are not being distributed intelligently.
Traditional systems assign travel orders sequentially: an order comes in, the next available operator gets it. Where that operator is currently positioned, which colleague would be closer, which combination of orders could be bundled on a single route — none of this is factored in by a human dispatcher in real time. The result: vehicles crossing paths in the warehouse, routes that overlap, and a fleet that is structurally larger than it needs to be.
Empty runs are not a discipline problem. They are a system failure.
Which measures actually reduce empty runs?
Not every measure works at the same depth. Here is an overview with an assessment of when each approach makes sense.
Summary: The first two options improve individual aspects. Only the third addresses the root cause: the missing real-time intelligence in order distribution.
What do too many empty runs actually cost?
The visible costs are diesel, electricity and tyre wear. The real costs are far greater.
How does AI-based order optimisation work and why is it different from a guidance system?
A classic forklift truck guidance system works with rules: Order A has Priority 1, goes to the next available operator. That is better than no system but it is not an intelligent system.
AI-based optimisation works with states.
identpro captures the exact position of every forklift truck in real time via LiDAR sensor technology — accurate to ±10 cm, updated every second. Based on this data, the optimiser continuously calculates the most efficient distribution of all open orders across all available vehicles: who is closest? Who has capacity right now? Which route can be combined with which follow-up order?
The result is not a gradual improvement. It is a different way of dispatching, one that a human dispatcher simply cannot perform in real time, because no one can simultaneously track the position of 20 vehicles and 50 open orders. According to identpro customer data, operations that switch to AI-based order optimisation achieve efficiency gains of 20–25%. In practice, that means: fewer vehicles for the same throughput, or more throughput with the same fleet.
Implementation requires no structural changes to the warehouse. Existing forklift trucks are retrofitted with LiDAR sensor technology, the system runs via Wi-Fi or LTE and integrates with SAP EWM, SAP WM and other ERP systems via standard interfaces.
Your fleet is larger than it needs to be.
Most operations only realise this once they start measuring.
How have other companies reduced empty runs with identpro?
JACO Grinding USA — Stone processing
JACO Grinding, with two production sites in North Tonawanda, NY, faced a classic fleet trap: over 2,000 containers were dispatched manually, with 3–4 employees occupied exclusively with locating containers every day. When a new production line was planned, the original calculation was clear: 10 additional employees would be required.
After implementing the identpro Warehouse Execution System with AI-based order optimisation, the new line ran with 2 employees instead of 10. The challenge was not solved by hiring more staff, but by distributing existing resources more intelligently. The results in numbers: 99% fewer search times and 15% more profitability in operations.
“The system completely transformed our company.” — Al Bluemle, CEO of JACO
ELA Container — Mobile space and building solutions
ELA Container manages around 60,000 containers across 18 locations worldwide. Without real-time transparency over vehicle positions and container locations, inefficient search trips, duplicate movements and lorry waiting times of up to 2 hours at loading arose daily.
After implementing the identpro WES, ELA operates with a search-free, optimised material flow. Orders are started without any back-and-forth, unnecessary detours are eliminated, and fleet utilisation improved measurably.
“Our specialist staff can now focus on what matters — and no longer lose time searching.” — Michael Gerdes, ELA Container
Frequently asked questions (FAQ) about empty runs and AI-based optimisation
What decision-makers typically want to know before reaching out.
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