Transparency as the basis for greater efficiency
"With Leadec TwinFleet, we create a digital twin of the intralogistics fleet in the factory. This provides our customers with an objective data basis for optimization—from efficient capacity utilization and route planning to sustainable investment decisions," explains Alexander Bonk, SVP Operations Germany at Leadec.
Leadec TwinFleet visualizes in real time how industrial trucks are actually being used. A set of sensors collects relevant data such as position, load and lift height. The information is transferred to the Leadec Industrial Cloud via a gateway, where it is aggregated and analyzed. A dashboard clearly displays the utilization of the fleet as well as usage patterns, and anomalies.
Fleet optimization: from experience to data
The goal of Leadec TwinFleet is to identify and improve processes and bottlenecks. The solution helps companies move from experience-based to data-based decisions. "For example, one of our customers had difficulties finding new employees for intralogistics. Today, the existing team can meet the increased demand thanks to more even workloads and time savings through optimized routes with more full trips,” says Alexander Bonk.
While the dashboard provides the evaluations, the real potential for improvement is developed in collaboration with the company utilizing the solution. The possibilities are manifold: based on the data, load peaks can be smoothed, improved order allocation with real-time information can be implemented, or suitable transfer stations can be identified to reduce distances. Another module—an RFID-based goods flow analysis—will be available shortly.
The digital twin also provides reliable information for investment decisions, such as selecting suitable battery types or determining future lifting heights and load capacities.
Efficient layout planning and greater safety
Visualizing movement profiles reveals potential for optimization not only in the fleet, but also in the warehouse layout. Heat maps highlight high-traffic areas and enable targeted adjustments to relieve critical zones. TwinFleet also increases occupational safety with warnings for overheight, speed monitoring in defined areas, and other analysis functions.
Leadec TwinFleet was developed as a joint research project between Leadec, Liebherr-Hydraulikbagger GmbH, Sick AG, and the Ferdinand Steinbeis Institute. Following a successful pilot phase, the solution is now available to all companies looking to optimize their intralogistics.
Live webinar on February 10, 2026
Leadec TwinFleet will be presented in detail for the first time in a live webinar on February 10, 2026, at 11 a.m.. The Leadec team will explain the technical setup, provide insights into the platform and demonstrate the optimization potential that can be leveraged with the help of the digital twin of the fleet.
Please register via the Leadec TwinFleet website.
