01
Client Profile & Background
A large automotive parts manufacturing company in Bekasi operates a 50,000 sqm plant with over 200 forklifts, 50 AGVs, and 100 delivery trucks daily. The facility has multiple production lines, warehouses, and loading docks spread across 10 buildings. The company produces 5,000 components per day and relies on just-in-time inventory, making traffic flow critical to avoid production stoppages.
The existing traffic management relied on manual coordination via radio and paper logs, leading to frequent bottlenecks at intersections and loading docks. The company needed a digital solution to monitor and optimize vehicle movements in real time, reduce collision risks, and improve throughput.
02
Technical Challenge
The plant experienced an average of 15 congestion events per shift, each lasting 10-15 minutes, causing a 12% loss in logistics efficiency. Forklift collisions occurred 3 times per month, resulting in costly damages and safety incidents. The manual tracking system had a 30-minute delay in reporting vehicle locations, making it impossible to react proactively.
Additionally, the plant lacked integration between traffic data and the WMS, leading to trucks waiting at wrong docks. The network infrastructure was insufficient to support IoT devices, with only 50% Wi-Fi coverage in the outdoor areas. The company required a solution that could handle 500+ concurrent devices with sub-second latency.
03
Implemented Solution
Intilogy deployed MILESIGHT LoRaWAN traffic sensors (model EM500-TH and AM100) at 40 critical points, including intersections, dock doors, and narrow aisles. These sensors detect vehicle presence and speed, transmitting data via LoRaWAN gateways to a central server. We installed Lenovo ThinkSystem SR650 edge servers running MILESIGHT's IoT platform for real-time analytics, with Synology RS3618xs NAS for 10TB of redundant storage. For networking, we deployed Cisco Catalyst 9300 switches and enterprise WiFi access points to ensure seamless connectivity across the plant. The system was integrated with the existing WMS via MQTT APIs, enabling automatic dock assignment. We also implemented Fortinet FortiGate 100F firewalls to segment the IoT network and protect against cyber threats.
04
Results & ROI
Post-deployment, congestion events dropped by 80% (from 15 to 3 per shift), and average wait times reduced from 12 minutes to 2 minutes. Forklift collisions decreased to zero, saving an estimated $50,000 per year in damage costs. Logistics efficiency improved by 25%, enabling the plant to handle 10% more daily shipments without additional resources. The real-time dashboard provided 99.9% accurate vehicle tracking with sub-second latency. RPO for traffic data was reduced to 1 hour, and backup via Veeam ensured zero data loss. The ROI was achieved within 8 months, with annual savings of $120,000 from reduced idle times and improved throughput.
