Wal-Mart has integrated ID Systems' RFID technology to track cranes and other vehicles across 12 U.S. distribution centers. According to Gene Merlo, deputy director of sales for ID Systems North America, the implementation of this system has achieved two key objectives: boosting productivity and optimizing vehicle usage within the facilities.
The project began with a pilot in the second half of 2005, followed by testing in smaller centers in 2006, and was later expanded to a larger facility in 2007. The system relies on a Vehicle Asset Communicator (VAC), a battery-powered device operating at 915 MHz, installed on each vehicle. This small computer communicates with the Wireless Asset Manager, a network of receivers placed throughout the center, using a dedicated air interface protocol. Data is then transmitted via wireless or Ethernet to a central server running ID Systems’ software.
This software tracks the location and sensor data from each tag, providing real-time information about the vehicle’s position, driver, and status—such as whether it is in use, shipping, or requiring maintenance. It also collects and aggregates vehicle data, offering insights into the entire lifecycle of each asset.
Before driving, Wal-Mart employees must interact with the VAC by scanning their ID badge. The VAC reads the passive RFID tag, verifies the driver's authorization, and allows them to proceed. If the driver is the first to operate a vehicle in their shift, the system prompts a safety check, which includes both automated diagnostics and manual inspections to ensure compliance with OSHA standards.
While operating, the VAC monitors the cargo area through weight sensors. For example, with forklifts, it detects if they are carrying goods, enabling managers to track productivity more effectively. With 100 vehicles and 80 drivers, managers can identify idle vehicles and optimize resource allocation. They can also assess how often employees transport goods, compare performance, and improve efficiency.
Merlo emphasized that this data helps reduce the number of vehicles or change their usage patterns, ultimately cutting costs. Forklifts, which range from $10,000 to $25,000, become more cost-effective when managed efficiently. Prior to this system, Wal-Mart used a warehouse management system, but it couldn’t fully measure employee performance.
ID Systems conducted thorough testing, including lab and real-world scenarios, ensuring the VAC operates without interference from other RFID systems like EPC Gen 2 hardware or existing Wi-Fi networks. The same system is also deployed by the U.S. Postal Service, highlighting its reliability and versatility.
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