Geozone monitoring
Real-time count of carts in each zone, with automatic notifications when carts arrive at or leave assembly lines, warehouses and staging areas.
Application
How a logistics operations manager brought transparency to thousands of transport assets (logistics carts, steel pallets and custom stillages) moving across production sites, supplier networks and customer locations. When one goes missing, it isn’t just an asset lost. It’s tens of thousands lost every month and a production line running blind.
Thousands of logistics carts, steel pallets and custom stillages circulate between production sites, suppliers and customer locations. The moment one leaves a controlled zone, visibility drops to zero. Teams count inventory by hand, guess where assets are, and keep repurchasing equipment that is sitting idle somewhere in the supply chain.
“At an industrial facility, flows may seem simple, but they are difficult to manage on a daily basis. Data has allowed us to objectively assess flows and base our decisions on factual evidence.”
Industrial equipment production doesn't stall because transport assets go missing. It stalls because of the chain of consequences when they can't be seen. Sensolus closes that visibility gap on four fronts.
Stop repurchasing carts, pallets and stillages by knowing exactly where every transport asset is at all times.
Replace fixed-schedule truck runs with data-driven collection based on which assets are actually ready for return.
Automated alerts flag overdue stillages and delayed returns, so you intervene before production is disrupted.
Swap spreadsheets and manual stock walks for automatic geozone counting that feeds straight into your BI tools.
The solution is simple to deploy, and after just a few months, we have already seen an increase of approximately 5% in the utilisation of our logistics carts.
What Vaillant achieved with Sensolus on a 1,600-cart fleet
Marc manages logistics operations at ProBuild*, a European manufacturer of industrial equipment and building components. Inside its main production plant, around 1,600 logistics carts and tuggers move parts between the warehouse, the assembly lines and the staging zones all day long. Until recently, he’d start most mornings guessing where carts were and counting them by hand.
Marc’s problem was never theft. Carts weren’t disappearing, they were simply untracked, so his team lost time hunting for them and kept buying replacements for carts that were sitting idle somewhere on site. Across a fleet of 1,600 in constant motion, the case for real-time visibility makes itself.
*ProBuild is a fictional use case created using an aggregation of data from multiple Sensolus customers in industrial equipment manufacturing.
Marc's carts rarely leave the plant, so the challenge was never the open road, it was the factory floor. Across assembly halls and warehouses, 1,600 logistics carts would regularly dwell too long or go misplaced in busy production zones. Not stolen, just untracked. Marc's team fitted each cart with a compact location tag and installed smart gateways at key zones: assembly lines, warehouse buffer areas and staging zones. The gateways pick up the tag signals and define geozones for indoor visibility. When the team needs to know where carts are piling up, or which have been sitting too long, the platform answers instantly, and automatic stock counting replaces the manual inventory walks.
Every cart carries a compact Bluetooth (BLE) location tag. Smart gateways placed around the plant scan the tags and report zone-level position back to one platform, so the whole fleet stays visible with no GPS hardware and no site wiring. Assets that travel between sites, such as steel pallets and stillages, can be tracked on the same platform with GPS smart trackers. At ProBuild the fleet is cart-based, so this story stays on the floor.
| Asset type | Quantity | Tracker | Update frequency | Purpose |
|---|---|---|---|---|
| Logistics carts | 1,600 | Location tag | Continuous (BLE) | Zone-level position, dwell time, flow tracking |
Marc used to discover problems only after they had already hit production. Now the Sensolus platform flags issues proactively on configurable rules, so his team only acts when something actually needs acting on.
Real-time count of carts in each zone, with automatic notifications when carts arrive at or leave assembly lines, warehouses and staging areas.
Alert when a cart sits in one place longer than its benchmark, flagging idle carts and ones parked in the wrong zone.
Zones about to run short of carts are flagged in advance, so Marc's team can rebalance the fleet before a line is starved.
Automated comparison of cart flow against zone benchmarks. Deviations trigger investigation, not guesswork, with data feeding directly into BI dashboards.
Minimal infrastructure. Cross-border continuity. BI integration that puts data where decisions are made. Everything else flows from these three.
Smart trackers and location tags deploy without changes to existing factory infrastructure. No wiring, no floor modifications, no IT project. Customizable and easy to install, local teams can deploy the solution themselves and replicate it globally across every site.
Patented data recovery ensures near-100% journey data across Europe and beyond, even through rural stretches with poor network coverage. Assets stay visible from production floor to customer site and back.
Sensolus data feeds directly into Power BI or your existing BI environment. No separate dashboard. Asset utilization insights appear where planners and production schedulers already make decisions.
The questions industrial equipment production, logistics and operations leaders ask us most when they start evaluating asset visibility.
No. Sensolus smart trackers work out of the box over public low-power cellular and GPS networks. No gateways, no receivers, no wiring, and no changes to your sites or your suppliers’ IT. A steel pallet can leave your production plant, cross a border, and arrive at a customer site without anyone touching infrastructure along the way.
For indoor, zone-level tracking of assets like logistics carts, Sensolus Bluetooth (BLE) location tags are picked up by smart gateways positioned in the building, or by existing third-party devices that act as a smart gateway, such as a handheld RFID reader.
Our trackers operate across European and international cellular networks and switch automatically as an asset moves across borders. Journey data stays continuous. No SIM swaps, no dead zones at the border, no separate contracts per country. Patented data recovery fills short connectivity gaps so every cross-border leg reaches near-100% continuity, even on routes through remote areas.
Yes. Outdoors and in transit, assets are located via GPS. Indoors, across assembly lines, warehouse buffers and staging zones, Sensolus location tags use Bluetooth (BLE) and are detected by smart gateways placed in the building. The platform gives a real-time count of assets per zone and replaces manual inventory walks with automatic stock counting.
Sensolus trackers are engineered for 5–10 years of battery life under typical transport-asset cycles, depending on configuration and reporting frequency. That’s longer than the working life of most returnable transport items. There are no charging stations, no swap-out cycles, and no maintenance overhead. Trackers are fit-and-forget for the lifespan of the asset.
Yes. Sensolus exposes location, journey, dwell-time and cycle-time data through a REST API and can stream events to your ERP, BI, or supply-chain platform. Customers typically pipe real-time asset state into tools like Power BI, SAP, Microsoft Dynamics or a custom planning system, so asset visibility shows up where planners and production schedulers already work.
Deployments are typically live within weeks, not months, because there’s no site infrastructure to install or approve. Visibility benefits appear from day one: knowing where every asset is, catching dormant and overdue assets early, and ending the manual counting.
Cost and inventory improvements build over the first 6–12 months as teams use cycle-time and dwell-time data to right-size the asset pool. Industry benchmarks point to up to -80% fewer lost assets over that horizon.
Yes. The solution is proven at a single facility and deployed across 10+ sites without infrastructure changes. Because trackers and tags are self-contained and easy to install, local teams can replicate the same setup themselves, making it a globally repeatable solution rather than a one-off project.
Whether you manage hundreds of pallets or thousands of carts, let's talk about what real-time asset visibility could look like for your operations.
Request demo© 2026 Sensolus - All rights reserved
