By equipping three forklifts with Sevensense's Alphasense Tracker for a six-day proof-of-value, ABB Smart Power in Alingsås, Sweden, mapped 8,000 m² of production and storage areas, logged 193 km of driving, and collected granular safety and utilization KPIs. Carl Troiza, Continuous Improvement Specialist at ABB Smart Power in Alingsås, said: "The Alphasense Tracker installed by Sevensense has supported two ongoing improvement projects, one of which focused on making our kitting process more efficient, and the other focused on reducing waste in our material handling in and around one of our production processes. The data provided has enabled us to quantify suspected improvement areas and has helped us visualize the work environment that surrounds our forklifts and processes."
Like many factories, the Alingsås site had strong instincts about where to improve forklift logistic flows and increase safety, but needed data to be sure. The site team wanted a low-friction way to validate those assumptions, quantify the impact, and build a business case for continuous improvement in material flow. Before the tracker, the unit had no precise measure of how much time forklifts actually spent driving versus standing still.
In October 2025, ABB Smart Power in Alingsås partnered with Sevensense to run the proof-of-value using Alphasense Tracker, a visual-SLAM-based real-time locating system (RTLS) for manual material handling trucks. Three forklifts were equipped, the facility was mapped, and traffic, utilization and safety indicators were recorded across day and night shifts without any external infrastructure. Each device was installed and configured in less than 30 minutes, drawing power from existing lines without affecting the vehicle's uptime. The forklifts themselves were used to map around 8,000 m² of production halls, storage tents and outdoor areas, producing a metrically accurate digital map shared across all three vehicles. Map updates ran automatically.
Recorded data was consolidated by operational task and by day. The KPIs tracked included distance driven, time in operation, time at standstill, utilization rate, average speed during operation, driving time above 10 km/h, and the number of shocks detected, meaning accelerations greater than 1.5G on the horizontal plane. Outputs included spaghetti diagrams, position and velocity heatmaps, a shock map and usage timelines. The position heatmap highlighted repeated stopping nodes where forklifts queued or waited, frequently used corridors, crossings with consistent pauses suggesting traffic conflicts, and rarely visited areas. Utilization rates were calculated for each operational task.
ABB Smart Power in Alingsås identified continuous fleet-wide tracking as the next step. With long-term data, the site could track how KPIs evolve as new layouts, schedules or traffic rules are introduced, and run before/after experiments on process changes.